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CLAIM OF PRIORITY
This Continuation-In-Part Application claims priority to U.S. patent application Ser. No. 10/459,337 filed Jun. 11, 2003 now U.S. Pat. No. 7,290,679 and U.S. Provisional Patent Application Nos. 60/501,683 Sep. 10, 2003, 60/577,699 Jun. 7, 2004, 60/587,783 Jul. 14, 2004, and 60/604,366 Aug. 25, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to insulating devices for beverage containers and more particularly, to insulating beverages and foods by using air as the insulator.
2. Background and Related Art
Disposable cups are routinely used in fast food and roadside restaurants to contain both hot and cold drinks. Because such cups have relatively thin walls, insulation is poor. As a result, the cups in which hot beverages are served are often too hot to hold comfortably, and the outside surface of cups in which cold beverages are served often accumulate moisture also making the cups difficult to hold, thus causing the holder's hand and the table to become wet. In addition, cold drinks warm quickly and hot drinks lose heat rapidly.
In response to the need for a better beverage insulator, various types of disposable cardboard and paper sleeves have been used. The sleeves are sized to slide onto the outside of a beverage cup and are held in place by friction. The wide-diameter end of the typical beverage cup prevents the sleeve from sliding off the cup while the cup is being held. However, such devices are poor insulators because they are generally thin. Moreover, the close contact with the cup causes additional heat transfer to the outside of the insulator. Additional insulation is needed at the bottom of beverage cups because the fluid has been there for a longer period of time. Also, such devices typically cover any printable material on the outside of the cup, resulting in a lost opportunity for advertising. While some transparent insulators have been created, they also lose effectiveness as insulators because of the close contact with the cups and the conductive material out of which they are typically made. Some of the more effective insulators are too bulky and take up too much storage space in small convenience stores, thus making the disposable cups too big to fit in most cup-holders. Another problem with most disposable cups is that since typical cups have narrow bases, they are unstable. Thus, there is a great need in the beverage industry for cups with better insulation and overall improvement.
To solve the problem of difficulty in gripping either hot drinks or cold drinks that accumulate moisture on the outside of the cup, some disposable cups include handles. Unfortunately, the problem with handles is that they are typically made out of paper or other sheet-like material and they lack sufficient strength to hold the cup in an upright position when the user is holding the cup by the handle. In other words, the weight of the cup can cause the handle to sag or tear such that the cup will tilt, spilling the beverage.
SUMMARY OF THE INVENTION
The present invention relates to insulating devices for beverage containers and more particularly, to insulating beverages and foods by using air as the insulator.
The preferred embodiment of the present invention involves a foldable air insulating sleeve configured to slidably receive and secure a beverage cup. The foldable air insulating sleeve secures the cup in a manner that allows for a pocket of air to surround the cup. This pocket of air insulates the beverage. The user can hold the cup by grasping the outer surface of the foldable air insulating sleeve, thus avoiding contact with a hot or wet cup surface. Because the bases of most disposable cups are narrower than their respective rims, more air and thus greater insulation is possible, especially towards the bottom of cups secured by the foldable air insulating sleeve. The wider base also gives the cup greater stability. Furthermore, the material out of which the foldable air insulating sleeve is made allows for advertisements or other printable material to be affixed on its outer surface. The foldable air insulating sleeve can be made out of many materials, including plastic or paper. The foldable air insulating sleeve is also foldable into a substantially flat position.
In this embodiment, the base of the cup rests on an inner base of the foldable air insulating sleeve. The inner base is connected to an outer base, which is in contact with the outer surface and supports the entire sleeve-cup configuration. The space between the inner and outer base is filled with air and further acts to insulate the contents of the cup.
In another embodiment, the foldable air insulating sleeve's outer base is in contact with the outer surface and supports the entire sleeve-cup configuration.
In yet another embodiment, the foldable air insulating sleeve's inner base has an opening through which the cup enters until the cup is either too wide and is stopped from further passage or until the cup meets the outer base of the foldable air insulating sleeve and is supported by it.
In even another embodiment, the foldable air insulating sleeve's outer base, while wider than the cup it supports, is narrow enough to fit into most cup holders.
In an additional embodiment, the foldable air insulating sleeve includes a lid that attaches to the top rim of the cup. The lid is substantially hollow, providing an air chamber, which further insulates the contents of the cup. When the foldable air insulating sleeve is used with food, the lid has no openings. When used with a cold drink, the lid has an opening through which a straw is placed. Finally, when used with a hot drink, the lid has a rounded mouth piece and a cap, the mouthpiece and cap being either separate or tethered.
While the methods and processes of the present invention have proven to be particularly useful in association with beverage containers, those skilled in the art will appreciate that the methods and processes can be used in a variety of different applications to insulate a variety of different kinds of temperature sensitive substances (e.g. soups and other foods).
These and other features and advantages of the present invention will be set forth or will become more fully apparent in the description that follows and in the appended claims. The features and advantages may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Furthermore, the features and advantages of the invention may be learned by the practice of the invention or will be obvious from the description, as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1A illustrates a short sleeve insulator with cup inserted.
FIG. 1B illustrates a folded short sleeve insulator.
FIG. 2A illustrates an opened short sleeve insulator.
FIG. 2B illustrates a transparent view of an opened short sleeve insulator with cup inserted.
FIG. 3A illustrates a transparent view of an opened short sleeve insulator.
FIG. 3B illustrates a view of an extended opened short sleeve insulator with cup inserted.
FIG. 4A illustrates a view of an extended folded short insulating sleeve.
FIG. 4B illustrates a view of an extended opened short insulating sleeve.
FIG. 5A illustrates a transparent view of an extended opened short insulating sleeve with cup inserted.
FIG. 5B illustrates a transparent view of an extended short insulating sleeve.
FIGS. 6A-20B illustrate exemplary embodiments of the short sleeve insulator.
FIG. 21A illustrates an exemplary selection of structural beams for wall of sleeve insulator.
FIG. 21B illustrates an exemplary selection of structural beams in insulating sleeve wall.
FIG. 22A illustrates an exemplary selection of openings for insulated lids.
FIG. 22B illustrates an exemplary embodiment of an insulating sleeve inside adapted holder.
FIG. 23A illustrates an exemplary embodiment of an adapted holder.
FIG. 23B illustrates a transparent view of an exemplary embodiment of an adapted holder.
FIGS. 24A-24B illustrate an adapted holder.
FIGS. 25A-25B illustrate an exemplary selection of structural beam layouts.
FIGS. 26A-29B illustrate an insulated sleeve with supports.
FIG. 30A provides an illustration of a flat insulating lid.
FIG. 30B provides an illustration of a cross-sectional view of a flat insulating lid.
FIG. 31A illustrates an insulated bubble lid.
FIG. 31B illustrates a cross sectional view of a bubble lid.
FIG. 32A illustrates an alternative exemplary embodiment of the bubble lid.
FIG. 32B illustrates an cross sectional view of the alternative exemplary embodiment of the bubble lid.
FIG. 33A illustrates an alternative embodiment of the insulating lid.
FIG. 33B illustrates a side view of the insulating lid.
FIG. 34A illustrates an alternative embodiment of the insulated lid.
FIG. 34B illustrates a side view of the alternative embodiment of the insulating lid.
FIG. 35A illustrates an alternative illustration of the insulating lid.
FIG. 35B illustrates an alternative side illustration of the insulating lid.
FIGS. 36A-37B illustrate an exemplary insulating sleeve.
FIGS. 38A-39B illustrate an exemplary alternative embodiment of an insulating sleeve.
FIGS. 40A-41B illustrate an exemplary alternative embodiment of an insulating sleeve.
FIGS. 42A-43B illustrate an exemplary alternative embodiment of an insulating sleeve.
FIGS. 44A-44B illustrate an exemplary alternative embodiment of an insulating sleeve with a ring in which a cup may sit.
FIGS. 45A-46A illustrate an exemplary alternative embodiment of an insulating sleeve.
FIG. 46B illustrates an exemplary alternative embodiment of an insulating sleeve with a ring in which a cup may sit.
FIGS. 47A-47B illustrate an exemplary alternative embodiment of an insulating sleeve.
FIGS. 48A-52A illustrate an exemplary alternative embodiment of an insulating sleeve.
FIGS. 52B-58 illustrate an exemplary mouthpiece.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to insulating devices for beverage containers, and more particularly, to insulating beverages and foods by using air as the insulator.
In the disclosure and in the claims the term “cup” shall refer to any container used to house consumable liquids and solids, or for insulating dishes full of food or liquid. Examples of cups include disposable cups, buckets, food storage containers, leftover food container, casserole dish containers, small soup bowls and any other similarly shaped container from which one drinks or eats that is in need of insulation.
By way of general description of the embodiments of the present invention, there is an air insulation barrier used to create a temperature gradient around the contents of a cup. The barrier may be an insulating sleeve that is placed around the exterior of a cup, or it may be a lid placed on the top of a cup. The barrier material may comprise paper, plastic, or a combination of the two. The invention as taught minimizes the amount of material needed to create the insulation barrier, as well as provide a user maximum choice in how to insulate the cup, making an insulating sleeve optional with the insulating lid, and vice versa. In addition, some embodiments of the present invention teach forming barrier shapes that can be folded to compact forms, and selectively expanded to a functional form. Finally, the invention teaches modifying the surface by applying material with a high friction coefficient to improve the user's grip of the invention.
Referring to FIGS. 1A-5B illustrating two exemplary embodiments of a short insulating sleeve 5 wherein said sleeve can selectively receive a cup 10 , the cup 10 and sleeve 5 having support rings 15 and forming an insulating air chamber 20 with a temperature gradient from the outer surface of the sleeve 25 to the temperature of the cup. The support rings 15 support the weight of the cup 10 while sheathed by the sleeve 5 , and provide the contact points between the cup 10 and the sleeve 5 . In addition, the support medially positioned support ring 15 provides increased support to the user gripping the sleeve, thus preventing the sleeve collapsing when held, and preventing the sleeve's outer wall 25 from contacting the cup 10 . The outer surface area 25 of the short sleeve is large enough to shield a user's hand from the surface of the cup 10 . Advantages of the short length of the sleeve are reduced manufacturing cost as well as the amount of storage space needed for several sleeves.
As illustrated in FIGS. 1B and 4A , the sleeve may be folded to minimize the profile of the sleeve. In addition, the sleeve may have indentations to allow the sleeve to fold along a desired axis.
FIG. 2A illustrates a sleeve without a cup inserted therein. The support ring 15 can support is rigid enough to keep the sleeve in an open form even when a cup is not inserted into the center of the sleeve. A manufacturing tab or tab 30 is on the outer edge of the ring and connects the ring 15 to the outer surface 25 .
FIG. 2 B's partially transparent view illustrates the insulating air chamber 20 that forms between the cup 10 and the sleeve 5 . Air is known as a superior insulation because of the difficulty gaseous molecules have in transferring kinetic energy.
FIG. 3B illustrates a sleeve 5 with a surface area 25 that extends 35 beyond the support rings 15 . This embodiment allows the rings 15 to be closer together while still providing a users' hand sufficient area to shield it from the temperature of the cup 10 .
Referring now to FIGS. 6A-20B illustrating several embodiments of the insulating sleeve 5 with a plurality of structural beams 40 to support the weight of the cup 10 . While the structural beams create more contact than other embodiments described herein, the beams provide superior support, thus allowing the user to sheath a cup of a variety of weights. The cup may be large or small and contain food or drink, and an appropriately sized insulating sleeve can still support the weight of the cup 10 .
FIGS. 6A through 7A show a short insulating sleeve that uses minimal material and provides minimal protection and insulation, while FIG. 7B illustrates a long insulated sleeve that provides the contents of the cup greater insulation by covering more of the cup's surface area, as well as provide greater protection for the user's hand.
FIGS. 8A , 10 B, 13 B, 15 B, 18 B and 20 B illustrate the insulating sleeve 5 folded to minimizing the storage area for the sleeve.
FIGS. 9 B and 10 A's transparent view of the cup 10 supported by the sleeve's 5 structural beams shows in detail the insulating air chamber 20 formed between the outer surface of the sleeve 25 and the surface of the cup 10 . Additionally illustrated is the extension of the sleeve 35 beyond the structural members 40 that allow the manufacturer to minimize the amount of material used in creating the structural members 40 while still providing the amount of surface area 25 needed to shield the user's hand from the cup. As illustrated, the sleeve may cover only a portion of the cup, or it may cover substantially all the cup.
FIG. 11A illustrates round half-spheres as structural members. Using round half-spheres to create the insulating air chamber further minimizes the amount of material needed to create the sleeve as well as the simplicity of mating the cup and sleeve. Using round half-spheres allows the user to slip the cup into the sleeve while it is still partially folded, because there are no rings or members to align.
FIGS. 12A and 12B illustrate an embodiment where the structural members 40 are round half spheres that create the insulating air chamber 20 between the surface of the sleeve 25 and the surface of the cup 10 . The length may be either short, covering only a portion of the cup's surface, or long covering substantially the entire length of the cup.
FIGS. 13A , and 14 A through 15 B illustrate a support structure comprising a tubular circle 40 along the sleeve's inner wall 45 . The continuous contact between the structural member 40 and the cup 10 provides greater support to the cup 10 when the weight of the cup 10 is great. In addition, the continuous contact of the structural member 40 with the cup 10 creates an insulating air chamber 20 with less air moving between the cup 10 and the sleeve 5 , thus providing insulation for the cup 10 .
FIG. 15A illustrates the teaching of the present invention wherein the number of structural support tubular rings 40 in increased with the length of the sleeve 5 to provide support for the user when gripping the sleeve 5 and cup 10 .
FIGS. 16A through 17B illustrate slanted half-circle structural beams 40 as both short and long.
FIGS. 18 A and 19 A- 20 B illustrate a flame structural beam 40 , which provides increased multi-directional friction between the cup 10 and both a short and long sleeve.
FIGS. 21A and 21B illustrate an exemplary selection of cross-sections used as structural members 40 .
FIG. 22A illustrates an exemplary selection of shaped openings in insulating lids 50 . The openings may be used for venting, passing a straw, or passing the contents of the cup. The insulating lid 50 , described below, helps create another temperature gradient around the cup to help insulate the cup's contents.
FIG. 22B illustrates an embodiment of an insulating sleeve 5 with cup inside in an adaptor 55 adapted to fit the sleeve 5 into a cup holder (not shown). Often, cup holders are sized so a cup fits snugly into the holder. If an insulating sleeve substantially increases the circumference of a cup, the user may be precluded from using the cup holder. By providing this embodiment, the user may use both an insulating sleeve 5 and a cup holder.
FIGS. 23A and 23B illustrate the adapter 55 used to fit the sleeve and cup into a cup holder. The adapter provides a wide receiving end for receiving the cup and insulating sleeve. In addition, the adapter adapts the wide end to a narrower end to fit into a standard cup holder. It is anticipated that the narrower end can be adapted to fit any size cup holder, including widening the cup and sleeve combination, including widening the base to fit between two armrests 60 .
FIGS. 24A through 24B illustrate adapter 55 widened to support 60 a drink and provide a working or resting surface in a theatre. Also anticipated are cup holders in cars, on airliners, at bars, as well as any other place commonly known in the art.
Referring now to FIGS. 25A and 25B , there is illustrated an exemplary selection of layouts for structural beams 40 on an insulating sleeve wall 25 and insulating lid 50 . In addition to those illustrated here, the present invention teaches any formation of structural beams commonly known in the art to provide rigidity and support to the sleeve and lid.
FIGS. 26A , 27 A, 28 A, and 29 A illustrate an exemplary selection of insulating sleeves 5 with a cup 10 inserted into the sleeve 5 , with the number of support rings 15 optimized to support the weight and size of the cup 10 . As discussed above, the support rings 15 create an insulating air chamber 20 between a set of support rings 15 or between a support ring 15 and the base 65 , that helps prevent the contents of the cup 10 from warming or cooling, as well as shield the hand of a person holding the cup 10 . The insulating sleeve 5 may cover part or substantially all the side of the cup 10 , depending on cost, manufacturing and storage considerations. The tabs 30 provide a support to attach the support rings 15 to the insulation sleeve. In addition, each ring makes a closed insulating air chamber 20 .
FIGS. 26B , 27 B, 28 B, and 29 B illustrate a folded insulated sleeve 5 as well as the positioning of the support rings 15 when folded. When the user unfolds the sleeve 5 and inserts the cup 10 , all the support rings are simultaneously forced open thus allowing the cup to slide inside the sleeve. The present invention teaches a foldable insulating sleeve 5 , modifiable to include the number of support rings 15 and an optional base 65 necessary to support the desired cup weight. As such, the number or arrangement and placement of support rings is taught by the present invention as such placement optimizes the performance of the sleeve 5 .
Referring to FIGS. 30A-35B which illustrate a cup 10 with the insulating lid 50 . The lid 50 is comprised of a top wall 70 , a bottom wall 75 , a brim clasp 80 that is releaseable coupleable to the brim 85 of the cup 10 . The top wall 70 and bottom wall 75 form the walls of the insulating air chamber 20 , the bottom wall lying in the brim plane 90 so as to allow the cup 10 to be filled to capacity with content, and not have to save space for the insulating chamber 20 . The lid 50 maximizes the storage capacity of the cup 10 by not filling the storages space with the insulating air chamber. However, the present invention also teaches minimizing the profile of the lid 50 by placing the insulating air chamber 20 below the brim plane 90 .
As discussed above in FIG. 25B , structural beams 40 may be placed in the air chamber 20 of the lid 50 to improve its structural integrity, as well as provide additional support to the container as a whole. Additional support may be necessary when the lid 50 performs functions in addition to covering the cup. Such functions may be providing a defined opening 53 through which a straw 95 may be inserted. A structural beam 40 would provide the necessary strength to prevent the allow the user to use a straw 95 without compromising the structural integrity of the lid.
An additional function may be to provide a content funnel 100 through which the contents of the cup may be funneled to the user's mouth. The content funnel 100 may be part of the insulating air chamber 20 , as shown in FIG. 33B , or the chamber 20 may end before reaching the funnel 100 as shown in FIG. 34B . To prevent cooling and spills, the funnel has a cap 105 .
FIGS. 31A and 31B illustrate another embodiment of the lid where structural supports 40 may improve the function of the bubble lid 110 . Due to the bubble lid's 110 concave up shape, structural beams 40 enhance the functionality of the lid, allowing contents to extend above the brim plane 90 , effectively increasing the storage capacity of the cup 10 , while still being insulated and covered by the bubble lid 110 . Again, the insulating air chamber 20 may be either on inside the lid to minimize the profile of the lid, as shown in FIG. 31B , or it may be outside on the outside of the lid to maximize the capacity of the cup. A defined opening 53 in the bubble lid 110 allows the user to insert a straw 95 .
An exemplary embodiment shown in FIG. 35 illustrates a cup 10 with a flat lid 50 comprising an insulating air chamber 20 above the brim plane 90 , and a brim clasp 80 coupled to the cup brim. This embodiment can be used for food storage, for example if a chicken restaurant wanted to keep a patron's food warm until it was consumed, the chicken could be placed in the cup, the cup placed in an insulating sleeve, and the insulating lid placed on the top of the cup. The same situation could be made for hamburgers or any other food. In addition, the lid 50 may be connected to another lid to form a clamshell design and keep the food contents warm. In addition, the present invention teaches all combinations of the described arrangement.
Referring now to exemplary embodiments illustrated in FIGS. 36A through 41B where show is a variety of insulating sleeve shapes that provide increased insulation for the cup. The shape of the sleeve may be substantially cylindrical, the walls of the sleeve being respectively parallel, thus creating larger insulating air chambers 20 at the bottom of the sleeve than at the top, when the cup is tapered at the bottom. This shape provides improved insulation at the bottom of the sleeve where the contents of the cup will be for the longest period of time. Furthermore, the present invention teaches placing the support rings 15 in positions so as to minimize the amount of air circulating from the areas next to the empty cup, and areas insulating filled portions of the cup. In addition, the ring 15 provides the sleeve with increased structural support, thus preventing the sleeve from collapsing when gripped or held by a user. Here, the insulating sleeve 5 extends the entire length of the cup 10 , so as to insulate substantially the entire cup 10 . The substantially cylindrical sleeve also provides a wider more supportive base for the cup, thus preventing potential spills or tipping of the cup while in the sleeve.
Additionally, the present invention teaches the bottom of the sleeve may comprise either a base 65 on which the cup 10 rests, or a support ring 15 through which the cup 10 passes. When the sleeve 5 is substantially cylindrical, the rings 15 must remain concentric, but also compensate for the change of the cup 10 size.
Referring now to FIGS. 42A through 52A , the present invention also teaches a tapered sleeve 5 so as to run substantially parallel to the walls of the cup 10 , as show. Alternative exemplary embodiments where the insulating sleeve 5 covers different lengths of the cup 10 , including approximately half of the cup's surface, three quarters of the cup's surface, and the entire length of the cup's surface. In addition, as discussed previously, the present invention teaches a support ring 15 that is flush with the top of the insulating sleeve 5 , and an alternative embodiment that illustrates the sleeve 25 extending 35 beyond the top ring. Again, the insulating sleeve 5 may be foldable, thus minimizing the volume of shipping or storing several sleeves at one time.
Referring now to FIGS. 52B through 58 , an exemplary embodiment of a mouthpiece 115 is illustrated, with alternative embodiments showing the beveled edge in FIGS. 53B , 55 B, and wide edge 125 in 57 B. The size of the edge may be modified depending on the content of the cup, or to improve the user's comfort when putting the mouthpiece to the mouth. The mouthpiece 115 may provide an additional thermal barrier when used in combination with the sleeve 5 and lid 50 creating an additional insulating air chamber above the highest support ring 15 . The mouthpiece may also provide a cooling surface when placed on the brim of a cup by allowing the hot contents of the cup to come into contact with a cool surface before being consumed by the user.
Thus, as discussed herein, the embodiments of the present invention embrace the field insulating devices for food or beverage containers. In particular, the present invention relates to insulating disposable cups by using air as the insulator. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A foldable air insulating sleeve for insulating beverage and food containers is herein provided. More particularly, the foldable air insulating sleeve secures a cup in a manner that leaves a pocket of air surrounding the cup. This provides for improved temperature regulation and sufficient thermal insulation to assist the user in firmly grasping and handling the cup despite excess heat or condensation caused by the temperature of the cup's contents. Because the bases of most disposable cups are narrower than their respective rims, more air and thus greater insulation is found towards the bottom of cups secured by foldable air insulating sleeves. The wider base also gives such cups more stability. Support rings may be placed medially in on the inside of the sleeve to strengthen the sleeve and prevent it from collapsing when held by a user. The sleeve may also be short so as to insulate a medial portion of a cup. Printable material can also be affixed on the foldable air insulating sleeve's outer surface for advertising or other purposes. Some embodiments of the foldable air insulating sleeve include a lid to further improve thermal insulation. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of patent application No. 14/353,079, filed Apr. 21, 2014; which was a §371 national stage filing of international application No. PCT/EP2012/067845, filed Sep. 12, 2012, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. DE 10 2011 084 802.9, filed Oct. 19, 2011; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a display and operating device having a display field which can be operated by a user by means of touch.
[0003] Touch-sensitive display fields in the form of touch displays or multi touch displays are used in a multiplicity of fields of application to reproduce and manipulate information. With such displays, different operating actions can be carried out by a user by touching said displays. One possible operating action is the changing of parameters by touching the display, for example using a keyboard displayed on the display or plus/minus arrows which can be used to vary the value of a parameter. It proves to be disadvantageous in this case that the adjustment of the value is often associated with a plurality of touch interactions by the user in the manner of typing, which can easily result in errors during input. Furthermore, the resolution or step size which is intended to be used to adjust a parameter value can be only inadequately changed by the user.
SUMMARY OF THE INVENTION
[0004] The object of the invention is to provide a display and operating device which can be used to easily and intuitively display and change parameters.
[0005] This object is achieved by means of the display and operating device as claimed and a method for controlling a display and operating device as claimed. Developments of the invention are defined in the dependent claims.
[0006] The display and operating device according to the invention comprises a display field which can be operated by a user by means of touch and can be operated, in a computer-assisted manner, in particular via a microprocessor of the device, for a number of parameter vectors (that is to say groups of parameters) each comprising one or more parameters, in an adjustment mode in which the values of the parameter(s) from a range of parameter values associated with the respective parameter are visualized on the display field and can be adjusted by means of operation by the user.
[0007] According to the invention, visualization in the adjustment mode is effected in such a manner that a respective parameter vector is represented on the display field by a number of ring elements corresponding to the number of parameters of the respective parameter vector, a respective ring element being associated with a parameter and being reproduced as at least one part of a circle or ring. In one preferred variant, a ring element is represented in this case as a complete circle or ring with an angular extent of 360°.
[0008] The values of the parameter from the range of parameters for a respective ring element are coded according to the invention using positions along the circumference of the respective ring element, and the adjusted value of the parameter is displayed at the position corresponding to the value on the circumference using a touch element. In this case, the touch element is reproduced, in particular, as a circle which preferably has a diameter in the range of the extent of a human fingertip.
[0009] According to the invention, the touch element is configured in such a manner that it can be arranged at different radial positions around the center of the respective ring element using a user interaction and can be rotated by the user in the circumferential direction of the respective ring element around its center by means of touch, and in particular by means of touch using his finger or using a pen, and movement on the display field, the parameter being adjusted to the value of the position along the circumference of the respective ring element by rotating the touch element, which position results from the intersection of the respective ring element with a line running between the center of the respective ring element and the touch element. In one preferred variant, the line is permanently reproduced on the display field in this case when manipulating the touch element. If necessary, however, the line may also be only a virtual line which is not apparent on the display field.
[0010] The display and operating device according to the invention makes it possible to easily and intuitively change parameters by accordingly rotating a touch element associated with a ring element. Positioning the touch element in different radial positions makes it possible in this case for a user to easily and intuitively adjust the resolution or step size with which he would like to change the values of the corresponding parameter of the ring element. This is enabled by virtue of the fact that the values from the range of parameter values of the parameter are coded using the circumferential positions of the ring element. That is to say, the further radially to the outside the touch element is during rotation around the center, the finer the adjustment becomes since a larger distance must be covered in the circumferential direction in order to change the parameter value.
[0011] In the display and operating device according to the invention, the range of parameter values for the corresponding parameter is given by a predefined sequence of values. These values are preferably mapped to the circumference of the ring element associated with the parameter in accordance with this sequence (that is to say in the clockwise or anticlockwise direction). The range of parameter values may relate to any desired variables. In one particularly preferred embodiment, the range of parameter values for one or more parameters of at least one parameter vector is given by a numerical range of values. In one preferred embodiment, the touch element is configured in such a manner that, for positioning at different radial positions, it can be moved in the radial direction of the respective ring element by the user by means of touch, and in particular by means of touch using his finger or using a pen, and movement on the display field. Depending on the application, the touch element can be moved outward and/or inward in the radial direction of the ring element. The touch and movement of the touch element in order to change its radial position preferably form a joint user interaction together with the touch and movement in the circumferential direction of the ring element.
[0012] In one particularly preferred embodiment, at least one parameter vector comprises a numerical value consisting of an integer digit and a fractional digit, the integer digit and the fractional digit representing respective parameters of the parameter vector. According to the invention, these can therefore be adjusted in a suitable manner using separate ring elements, thus achieving fine adjustment of the corresponding numerical value.
[0013] In another particularly preferred embodiment, the extent of a respective ring element in the circumferential direction is used to code the entire range of parameter values for the parameter associated with the ring element. As a result, the range of parameter values is visually conveyed to the user in a simple manner using the extent of the ring elements.
[0014] In another refinement of the display and operating device according to the invention, at least one parameter vector comprises a plurality of parameters, the ring elements associated with the parameters being arranged concentrically around a common center. As a result, the adjustable parameters of a parameter vector are reproduced in a compact manner on the display field. In another refinement of the invention, the value of the parameter corresponding to the respective position is reproduced in textual form (that is to say on the basis of characters and, in particular, numerical digits) at one or more positions along a respective ring element, as a result of which the user is provided with clues as to how the values of the parameters change during rotation of the touch element. In another variant of the invention, the adjusted values of the parameters are also reproduced in textual form on the display field, with the result that the user is immediately provided with visual feedback on the value which has just been adjusted when manipulating the touch element.
[0015] In another embodiment of the display and operating device according to the invention, a value of a parameter which has been newly adjusted by the user can be confirmed by a user interaction. The confirmation is intended to result in the adjusted parameter being definitively adopted in the corresponding system represented on the display field. The user interaction for confirming the parameter preferably involves the user ending touch of the touch element, whereupon the touch element is automatically adjusted to the position corresponding to the newly adjusted value of the parameter on the circumference of the ring element. This can be visually conveyed, for example, by virtue of the actuating element automatically moving toward the ring element along the line between the center of the corresponding ring element and its current position.
[0016] In another preferred embodiment of the display and operating device according to the invention, the segment of the respective ring element between the starting value of the range of parameter values and the position corresponding to the adjusted value of the parameter on the circumference of the ring element is visually highlighted. The segment therefore represents a corresponding sector of a ring or circle. For example, this segment is represented in a different color than the remaining area of the ring element. As a result, the current value of the parameter for the corresponding ring element can be reproduced in the manner of a filling level.
[0017] In one preferred variant, the parameter(s) of a respective parameter vector comprise(s) control and/or regulating variables of a technical installation, the display and operating device interacting with the technical installation in such a manner that it transmits newly adjusted control and/or regulating variables to the technical installation, whereupon the technical installation can adopt the new settings for the control and/or regulating variables.
[0018] In another particularly preferred embodiment, the display field of the display and operating device can be operated in such a manner that a structure comprising a multiplicity of elements and, in particular, a technical installation is reproduced on the display field, a user being able to select the respective elements using a user interaction, whereupon a change is made into the adjustment mode for a number of parameter vectors associated with the selected element. In this mode, the parameters of the corresponding parameter vectors can then be visualized using ring elements, as described above, and touch elements can be adjusted.
[0019] The technical installation which is reproduced on the display field and the parameters of which are adjusted may relate to any desired fields of application. In one preferred variant, the structure is a technical installation, in which case the term “technical installation” should be broadly understood and may comprise a branched network of different technical components. In particular, the structure may relate to an energy supply and/or energy distribution installation, a telecommunication installation, a traffic monitoring installation, a power plant, an automation installation for process or production automation and/or a medical device.
[0020] In addition to the display and operating device described above, the invention also relates to a method for controlling a display and operating device in a computer-assisted manner, comprising a display field which can be operated by a user by means of touch and is operated, for a number of parameter vectors each comprising one or more parameters, in an adjustment mode in which the values of the parameter(s) from a range of parameter values associated with the respective parameter are visualized on the display field and can be adjusted by means of operation by the user. In this method, a respective parameter vector is represented on the display field by a number of ring elements corresponding to the number of parameters of the respective parameter vector, a respective ring element being associated with a parameter and being reproduced as at least one part of a circle or ring. The values of the parameter from the range of parameter values for a respective ring element are coded in this case using positions along the circumference of the respective ring element, the adjusted value of the parameter being displayed at the position corresponding to the value using a touch element.
[0021] In the method according to the invention, the touch element is animated on the display field in such a manner that it can be arranged at different radial positions around the center of the respective ring element using a user interaction and can be rotated in the circumferential direction of the respective ring element around its center by the user by means of touch and movement on the display field, the parameter being adjusted to the value of the position along the circumference of the respective ring element by rotating the touch element, which position results from the intersection of the respective ring element with a line running between the center of the respective ring element and the touch element. The method can therefore be used to control the display and operating device according to the invention. In particular, the method is configured in this case in such a manner that one or more of the preferred embodiments of the display and operating device according to the invention can also be controlled.
[0022] The invention also relates to a computer program product having program code which is stored on a machine-readable carrier and is intended to carry out the method according to the invention if the program code is executed on a computer. The invention also comprises a computer program for carrying out the method according to the invention if the program runs on a computer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] Exemplary embodiments of the invention are described in detail below using the accompanying figures, in which:
[0024] FIG. 1 shows a schematic illustration of one embodiment of a display and operating device according to the invention in the form of a multi touch display;
[0025] FIGS. 2 to 4 show illustrations of the operation of the multi touch display in FIG. 1 for the purpose of adjusting parameters on the basis of annular elements according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 shows a schematic illustration of a display and operating device according to the invention in the form of a multi touch display D, on the display field of which a network-like structure comprising a multiplicity of elements E (for example in the form of pictograms) is reproduced. Depending on the application, the network-like structure may relate to any desired systems or installations. In particular, it may be the illustration of an energy production and energy distribution installation, a telecommunication installation, a power plant, a process installation, a traffic monitoring installation and the like. The multi touch display is preferably an operating table which is installed in a control room for monitoring the corresponding system or the corresponding installation. In this case, the individual elements E are components of the corresponding network or the corresponding installation. A human operator can use the multi touch display to monitor the operation of the installation and to suitably change corresponding parameters of the individual elements E presented. In the embodiment in FIG. 1 , this is achieved by virtue of the operator using his finger to tap a corresponding element E whose parameter he wishes to change, whereupon the circles C schematically illustrated in FIG. 1 are displayed to the operator. Each individual circle C is composed of annular elements which are described in more detail using FIGS. 2 to 4 . The respective circle can be used to simply and intuitively change a process variable by touching the display. Technologies which are known per se can be used to implement the multitouch display D. For example, the display may comprise, on its underside, an optical system which is implemented by means of rear projection. In this case, the rear side of the display is illuminated using infrared emitters and touch on its top side is tracked on the basis of the change in the reflection behavior using an infrared camera behind the display. A further possible implementation of the display involves recognizing patterns on the basis of the so-called pixel sense technology in which infrared sensors sit in each individual pixel of the display and are used to detect touch on the surface by virtue of the change in the reflection behavior. If appropriate, it is also possible for the multi touch display to be implemented in a manner known per se by means of a capacitive touch surface, as is usually used in smart phones. One of the circles C illustrated in FIG. 1 for the correspondingly selected element is reproduced in an enlarged form in FIG. 2 . If appropriate, it is also possible in this case for the user to have the circles displayed on an enlarged scale in a separate area of the display using a suitable interaction. A new image on the display can likewise be constructed with an enlarged illustration of the circle.
[0027] The changing of a process variable which is carried out using the circle on the basis of the adjustment of a numerical value between 0.0 and 99.99 is described below using FIGS. 2 to 4 . However, the invention is not restricted to numerical values and it is also possible, if appropriate, to adjust process variables with other values using the circle C. According to FIG. 2 , the circle C comprises an outer ring R 1 and an inner circle R 2 , the outer ring R 1 reproducing the integer digit P 1 and the inner circle R 2 reproducing the fractional digit P 2 of a process variable PV. This process variable is a parameter vector in the sense of the claims. The value of the process variable PV is reproduced in textual form at the top right beside the circle C. In the scenario in FIG. 2 , the integer digit P 1 is adjusted to the value 11 and the fractional digit P 2 is adjusted to the value 14 . The ring and the circle are arranged concentrically around a common center M, and the corresponding range of values for the integer digit and the fractional digit of the process variable PV is coded by the total circumference of the ring or circle. That is to say, 360° of the outer ring R 1 corresponds to the range of values for the integer digit between 0 and 99, whereas 360° of the inner circle corresponds to the range of values for the fractional digit between 0 and 99.
[0028] The current value of the integer digit and fractional digit is visualized using touch elements or anchor points B 1 and B 2 which are arranged on the outer edge of the ring R 1 and of the circle R 2 . The corresponding value of the integer digit and ractional digit is indicated by the position of these touch elements with respect to the vertical line running through the center M. The value is also intuitively indicated by highlighting the ring segment or circle segment between the vertical line and the position of the corresponding touch element. The ring segment for the integer digit is denoted RS 1 in FIG. 1 and the ring segment for the fractional digit is denoted RS 2 . In this case, the highlighting can be achieved by presenting the segment in a separate color which differs from the rest of the circle or ring. In order to illustrate the range of values in which the integer digit and the fractional digit can be moved, four text fields which are offset by 90° with respect to one another are also reproduced on the outer edge of the ring R 1 and are denoted with reference symbol T. It is seen that an angular position of 0° corresponds to the numerical value 0, an angular position of 90° corresponds to the numerical value 25, an angular position of 180° corresponds to the numerical value 50 and an angular position of 270° corresponds to the numerical value 75.
[0029] The integer digit and fractional digit of the process variable PV are changed using the two touch elements B 1 and B 2 which constitute corresponding anchor points for the user's finger, as explained below. According to FIG. 3 , a user would like to change the integer digit P 1 . For this purpose, the user uses the finger F of his hand H to grip the anchor point B 1 which is originally on the edge of the outer ring R 1 . He can both pull this anchor point outward and push it inward and can also rotate it in the circumferential direction (that is to say tangentially) around the center M of the circle C. After the anchor point has been gripped, the line L is also continuously reproduced between the center M and the touch element B 1 . The value of the integer digit is increased or reduced by rotating the anchor point in the clockwise direction or in the anticlockwise direction around the center M. In this case, the current value of the integer digit is represented by the intersection of the line L with the outer ring R 1 , the size of the corresponding ring segment RS 1 being changed at the same time. In the scenario in FIG. 3 , the user used his finger F to first of all pull the touch element B 1 outward and finally to rotate it through an angle, with the result that the integer digit P 1 of the variable PV has changed from the value 11 to the value 19 . The user can also change the fractional digit P 2 of the process variable PV in the same manner by gripping and moving or rotating the anchor point B 2 . As clearly emerges from FIG. 3 , the adjustment of the integer digit is finer, the further the user pulls the anchor point B 1 outward since the corresponding values of the parameter are coded using the circumferential positions on the ring R 1 . That is to say, the further to the outside the touch element B 1 is, the greater the distance to be covered by the finger F in the circumferential direction in order to accordingly change the value.
[0030] After the user has adjusted the integer digit to the desired value 19 in the scenario in FIG. 3 , he can confirm this input in a simple manner by removing his finger from the touch element on the display field. Consequently, the process variable which has been newly adjusted is then adopted by the corresponding element of the system represented on the display. Releasing the anchor point also results in the touch element which has been released being reproduced on the edge of the corresponding ring or circle again, which is shown in FIG. 4 . According to this illustration, in comparison with FIG. 3 , the touch element B 1 has been adjusted at the position of the integer digit with the numerical value 19 on the edge of the outer ring R 1 .
[0031] The embodiment of the invention described above has a number of advantages. The practice of coding corresponding values from a range of values to the circumferential position of a ring or circle and the practice of changing this position using a touch element make it possible for the corresponding parameter value to be simply and intuitively changed, the speed of the change being able to be suitably adjusted by the user by selecting the radial position of the touch element. The further the user pulls the anchor point outward, the more finely he can adjust the corresponding value, whereas the adjustment becomes coarser, the closer the anchor point is to the center. During manipulation of the touch element, the current value of the parameter is displayed to the user by means of a line L, with the result that the user is always provided with visual feedback on the value which has just been adjusted, which is also supported by highlighting the ring segment corresponding to the adjusted value. | A display and operating device has a touch-sensitive display field by way of which the parameters of a parameter vector can be changed. In order to set the parameters, a structure of circular or annular elements is displayed, on the circumference of which a corresponding contact element is positioned. Using the position of a contact element on the circumference of the ring element, the value of the parameter is coded. The contact element is moved by user interaction to different radial positions about the center of the respective ring element to change the parameter value along the display field in the radial direction, and rotated in the circumferential direction of the ring element. The resolution of the parameter adjustment can be established in a simple and intuitive manner by selecting the radial position of the contact element during its rotation. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to web processing machines, particularly to semi-rotary web processing machines.
[0003] 2. Background Art
[0004] Web processing machines using a rotating tool cylinder processing successive sections of a continuous web of material include for example machine performing die cutting, laminating, stamping, printing, and coating. The successive sections are usually identical (i.e. repeats), and can be for example shapes to be cut, printed images, etc. The rotating tool is usually required to have the same tangential speed as the linear speed of the web when the tool is used to process each section of the web.
[0005] When the speed of the tool cylinder rotation and of the web are constant, the length of one section of web to be processed is usually equal to the circumference of the tool cylinder. As such, changing the length of the sections usually implies changing the tool cylinder. To reduce costs, a number of semi-rotary processes have emerged, allowing the use of a single tool cylinder for various sizes of web section. In most cases however, the modules performing the semi-rotary process cannot be used in series with other modules, since the web exiting the module usually travels at an intermittent speed, and as such is not compatible with a rotary process.
[0006] In web processing it is often desirable to perform multiple operations on a web, for example printing, laminating and cutting, through the use of several modules, one per operation to be performed, installed in series, i.e. with the web circulating through the modules and from one to the other in a continuous fashion. However, in such series the modules are usually dependent on one another for maintaining the web in tension, and as such a registry error at one module is reflected in all the downstream modules. As such, registry of the web at each module can be a complex procedure, usually done through modifying the speed or position of the multiple tool cylinders.
SUMMARY OF INVENTION
[0007] It is therefore an aim of the present invention to provide an improved web processing machine.
[0008] It is also an aim of the present invention to provide an improved method for processing a web.
[0009] It is a further aim of the present invention to provide an improved system for conveying a web between a tool cylinder and a corresponding anvil cylinder.
[0010] Therefore, in accordance with the present invention, there is provided a web processing assembly for a web processing module, the assembly comprising first, second and third fixed spaced apart pairs of nip rollers moving the web at a first, second and third speeds, the first and third speeds being constant and similar, the second speed being variable with a mean speed similar to the first and third speeds, and a first idler roller engaging the web between the first and second pair of rollers and a second idler roller engaging the web between the second and third pair of rollers, each of the first and second idler rollers maintaining the web in constant tension by moving along a restrained path perpendicular to an axis of the respective one of the first and second idler rollers to compensate for a difference between the variable second speed and the respective one of the constant first and third speeds.
[0011] Also in accordance with the present invention, there is provided a web processing machine for processing a web of material having a series of successive sections to be processed, the web processing machine comprising a constantly rotating tool cylinder having a predetermined circumferential length with at least a portion of the circumferential length defining at least one raised tool for processing an individual one of the sections, the tool rotating at a given tool tangential speed, a first pair of rollers upstream of the tool cylinder, the first pair of rollers pressing the web material therebetween and driving the web material at a first constant speed a second pair of rollers upstream of the tool cylinder and downstream of the first pair of rollers, the second pair of rollers pressing the web material therebetween and driving the web material at a cycling speed following a cycle corresponding to one rotation of the tool cylinder, the cycling speed corresponding to a mean speed similar to the first constant speed, the cycle including a period of constant speed similar to the tool tangential speed where the web travels in synchronism with the at least one tool processing a respective one of the sections, and a period of variable speed performing a re-register of a next one of the sections with the tool for the next rotation of the tool cylinder, the tangential speed being a function of the mean speed such that the at least one tool will be in register with the respective one of the sections, and a third pair of rollers downstream of the second pair of rollers, the third pair of rollers pressing the web material therebetween and driving the web material at a third constant speed similar to the first speed.
[0012] Further in accordance with the present invention, there is provided a method of processing a web comprising the steps of conveying a web into a first processing module at a constant speed, conveying the web through the first processing module at a first speed while maintaining a first tension on the web, the first speed having a mean corresponding to the constant speed, processing the web with a rotating tool in the first processing module, conveying the web from the first processing module to a second processing module at the constant speed, conveying the web through the second processing module at a second speed while maintaining a second tension on the web, the second tension being independent of the first tension, the second speed having a mean corresponding to the constant speed; and processing the web with a second rotating tool in the second processing module.
[0013] Further yet in accordance with the present invention, there is provided a system for conveying a web between a tool cylinder and a corresponding anvil cylinder, the system comprising a first motor driving the web upstream of and in proximity to the tool cylinder, a second motor driving the anvil cylinder, the anvil cylinder driving the tool cylinder, a third motor driving the web upstream of the first motor, a fourth motor driving the web downstream of the second motor, a first sensor sensing the position of a section of the web in proximity of the tool cylinder and generating first position data, a second sensor sensing the position of the tool and generating second position data, and a controller receiving the first and second position data, directing the first motor to drive the web at a cycling speed according to the first and second position data, and directing each of the second, third and fourth motors to drive the web at a constant speed similar to a mean speed of the first motor.
[0014] Further yet in accordance with the present invention, there is provided a method of processing a web, the method comprising the steps of constantly rotating a tool cylinder with an anvil cylinder, the tool cylinder having a circumferential surface defining a tool, moving a web between the tool cylinder and the anvil cylinder at a variable speed, subsequently detecting the position of each section to be processed on the web, detecting the position of the tool for each of the sections to be processed, and re-registering each section to be processed with the tool by adjusting the variable speed according to the position of the tool and the position of the section to be processed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment of the present invention and in which:
[0016] FIG. 1 is a front view of a web processing module according to an embodiment of the present invention;
[0017] FIG. 2 is a front view of a web processing machine including the web processing module of FIG. 1 placed in series with a similar web processing module;
[0018] FIG. 3 is a block diagram of the control system of the web processing module of FIG. 1 ;
[0019] FIG. 4 is a flow chart illustrating the progression of the web in the web processing module of FIG. 1 or, similarly, in the first web processing module of FIG. 2 ;
[0020] FIG. 5 is a flow chart illustrating the progression of the web in the second web processing module of FIG. 2 ; and
[0021] FIG. 6 is an alternative embodiment of the tension maintenance system for the web processing module of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring now to FIG. 1 , a web processing module 10 according to the present invention is schematically shown. The web processing module 10 includes a body 14 supporting a web processing assembly 12 , an unwind roll 16 preferably including lateral registering means (not shown), a tool cylinder 78 driven by an anvil cylinder 80 , and rewind roll 24 . The web processing assembly 12 allows a web 20 to be pulled from the unwind roll 16 at a constant speed, processed by the rotating tool cylinder 78 at a cycling speed or a constant speed, as required, and rewound on the rewind roll 24 at a constant speed. The web 20 can be, for example, paper, plastic film, label stock, etc. The unwind and/or rewind rolls 16 , 24 can be omitted if the web processing module 10 receives the web 20 from and/or feeds the web 20 to another web processing module.
[0023] The tool cylinder 78 can be, for example, a printing cylinder, a stamping cylinder, a die cutting cylinder, an embossing cylinder, a coating cylinder, etc. The tool cylinder 78 preferably includes a changeable plate around at least part of its circumference, with the plate defining a raised tool on a portion of the circumference only. The portion of the circumference not occupied by the tool does not contact the web 20 when it is aligned therewith. The raised tool corresponds to the length of the sections of the web 20 to be processed, and as such the same tool cylinder 78 , with different plates, can be used with different section lengths. In a preferred embodiment, the tool cylinder 78 is magnetic, and the plates are flexible metallic plates adhered thereto. The anvil cylinder 80 is preferably a hardened steel roller and rotates at a constant speed.
[0024] The tool cylinder 78 can alternatively include a changeable plate defining a tool along its entire circumference. The tool can also be integral with the tool cylinder 7 , with the tool being defined along part of or the entire circumference of the tool cylinder 78 . The tool cylinder 78 can also be changed for a tool cylinder 78 of a different size, as required, without changing the remaining elements of the web processing assembly 12 .
[0025] As shown in phantom, the body 14 can also support unwind and rewind rolls 18 , 19 for lamination material 22 , which can be processed together with the web 20 . The body 14 can also support a plurality of additional rewind rolls 26 , 27 for the web 20 or for waste material 28 which could be, for example, the waste matrix created during the process of die cutting.
[0026] The web processing assembly 12 includes a first cassette 30 pulling the web material 20 from the unwind roll 16 or from another upstream process. The first cassette 30 includes a first drive roll 32 , a first nip roll 34 pressed against and under the first drive roll 32 , and preferably a first nip idler 36 under the first nip roll 34 . The first nip roll 34 is frictionally driven by the first drive roll 32 . The first cassette 30 is located just downstream of the unwind roll 16 , the web 20 being circulated from the unwind roll 16 in a “S” pattern under and around the idler 36 , and between the nip roll 34 and drive roll 32 . The nip roll 34 and drive roll 32 apply pressure to the web 20 so that it is essentially clamped, i.e. the web will not slide upon applying pressure thereto. The first cassette 30 pulls the web at a constant speed.
[0027] The web processing assembly 12 also includes, downstream of the first cassette 30 , a second cassette 38 . The second cassette 38 includes a second drive roll 40 and a second nip roll 42 pressed against and under the second drive roll 40 to be frictionally driven thereby. The second cassette 38 is located just upstream of the tool and anvil cylinders 78 , 80 , with a plane being nearly tangential to the top of the drive roll 40 and to the bottom of the tool cylinder 78 . The web 20 is circulated in a “S” pattern under the nip roll 42 , between the nip roll 42 and drive roll 40 , and over the nip roll 42 to go between the tool cylinder 78 and anvil cylinder 80 and over an idler roll 82 located downstream thereof. The nip roll 42 and drive roll 40 also apply pressure to the web so that it is essentially clamped. The second cassette 38 coordinates the movement of the web 20 with the constant rotating movement of the tool cylinder 78 such that each section to be processed is in register with the tool. The second cassette 38 pulls the web at a cycling speed. The mean value of the speed of the second cassette 38 is substantially equal to the constant speed of the first cassette 30 . In cases where the circumference of the tool cylinder 78 is the same as a length of an individual section of the web 20 to be processed, the cycling speed corresponds to a constant speed (i.e. rotary process).
[0028] The web processing assembly 12 also includes, downstream of the second cassette 38 and of the tool cylinder 78 , a third cassette 44 . The third cassette 44 includes a third drive roll 46 and a third nip roll 48 pressed against and under the third drive roll 46 to be frictionally driven thereby. The web 20 is circulated in a “S” pattern under the nip roll 48 , between the nip roll 48 and drive roll 46 , and over the nip roll 46 to go to the rewind roll 24 or to another downstream process. The nip roll 48 and drive roll 46 also apply pressure to the web so that it is essentially clamped. The third cassette 44 pulls the web at a constant speed substantially equal to the constant speed of the first cassette 30 .
[0029] The web processing module 10 can also include one or more additional cassettes 50 for driving lamination material, waste material, etc.
[0030] In order to maintain adequate tension of the web 20 between the cassettes 30 , 38 , 44 as well as to provide a smooth transition for the web 20 between the constant speed and the cycling speed, the web processing assembly 12 includes a tension maintenance system 122 including first and second dancer assemblies 52 , 54 . The first dancer assembly 52 includes a first set of arms 56 , the body of which preferably include a plurality of holes 58 for weight reduction purposes. The first set of arms 56 is pivotable about a first pivot 60 on one end, and supports a first idler roller 62 on the other end. The first idler roller 62 engages the web 20 between the first and second cassettes 30 , 38 and applies a given tension thereto. The second dancer assembly 54 similarly includes a second set of arms 64 with holes 66 , pivotable about a second pivot 68 and supporting a second idler roller 70 . The second idler roller 70 engages the web 20 between the second and third cassettes 38 , 44 and applies the same given tension thereto. To maintain the tension, the first and second sets of arms 56 , 64 each include a bracket 72 , 74 which are interconnected by an adjustable pneumatic cylinder 76 .
[0031] The first and second idler rollers 62 , 70 , being each located between a constant and a cycling drive of the web 20 , undergo a reciprocating motion under the action of the web 20 and as such act as a transition between the two driving modes. This reciprocating motion is directed along a restrained arcuate path defined by the rotation of the first and second pivotable set of arms 56 , 64 . The idler rollers 62 , 70 maintain a constant tension on the web 20 , which is adjusted through the pneumatic cylinder 76 .
[0032] Numerous alternative configurations for the two idler rollers 62 , 70 are also possible, one of which is the combination of the two pivots 60 , 68 to have each set of arms 56 , 64 independently pivotable about a single pivot axis.
[0033] Another alternative configuration is illustrated in FIG. 6 , where the first and second idler rollers 62 , 70 are respectively connected to a first and second cable or chain 86 , 88 . The two cables 86 , 88 are each directed by a respective pulley 90 , 92 and interconnected by the pneumatic cylinder 76 , so that the idler rollers 62 , 70 can undergo a vertical motion. Additional fixed idlers 94 , 96 direct the web 20 to accommodate the vertical motion of the idler rollers 62 , 70 .
[0034] Alternatively, the pulleys 90 , 92 can be replaced by additional fixed idlers orienting the web 20 to accommodate a horizontal motion of the idler rollers 62 , 72 , which are connected by cable or chain portions to the pneumatic cylinder 76 .
[0035] The idler rollers 62 , 70 can also be separate from each other, with their movement being coordinated electronically. The pneumatic cylinder 76 can be replaced by other means to create tension, such as an hydraulic cylinder or a spring system. In any case, the idler rollers 62 , 70 have to maintain the web 20 in tension while each is moveable along a restrained path perpendicular to its axis to compensate for the speed differential of the web 20 , with the tension of the web 20 preferably being adjustable.
[0036] The web processing assembly 12 is controlled through the system illustrated in FIG. 3 . A controller 110 sends a speed signal to four electronically controlled motors 112 , 114 , 116 , 118 respectively driving the first drive roll 32 , second drive roll 40 , third drive roll 46 and anvil cylinder 80 , with the anvil cylinder 80 driving the tool cylinder 78 (see FIG. 1 ). The signal sent to the first drive roll motor 112 is preferably the reference signal and as such is constant, so that the first drive roll motor 112 always rotates at the same constant speed. The third drive roll motor 116 and the anvil cylinder motor 118 both rotate at a constant speed, while the second drive roll motor 114 can rotate at a cycling speed, as will be further explained below.
[0037] While the web 20 is passing through the web processing assembly 12 , the controller 110 receives a plurality of signals allowing it to adjust the speed of the remaining motors 114 , 116 , 118 . A web sensor 84 , for example a contrast sensor, is preferably located in proximity to the second cassette 38 , as close as possible to the tool cylinder 78 (see FIG. 1 ). This web sensor 84 determines the position of the section to be processed on the web 20 , and send a signal to the controller 110 accordingly. A tool sensor 120 is also preferably provided to read the position of the tool on the tool cylinder 78 and send a signal to the controller 110 .
[0038] In cases where the length of an individual section of the web 20 is different from the circumference of the tool cylinder 78 , the web processing assembly 12 will perform in a semi-rotary manner. The controller 110 sends a cycling speed signal to the second drive roll motor 114 to compensate for the difference between the portion of the circumference of the tool cylinder 78 not covered by the tool and the distance between successive sections to be processed in the web 20 . Thus, the cycling speed of the second drive roll motor 114 varies according to a cycle corresponding to a rotation of the tool cylinder 78 . When the web 20 is in contact with the tool to process one section, the second drive roll motor 112 will drive the web 20 at a constant speed which is equal to the tangential speed of the tool. When the web 20 is not in contact with the tool, the second drive roll motor 112 will drive the web 20 at a variable speed allowing the web 20 to “catch up” to or “wait” for the next rotation of the tool, depending whether the circumference portion of the cylinder 78 is longer or shorter than the length of an individual section to be processed in the web 20 . When the length of an individual section is shorter, the variable speed preferably includes a negative speed component, such that the web is intermittently “pulled back”.
[0039] The cycling speed can be fixed, i.e. calculated by the controller following parameters of the web section and tool such that each cycle is the same during the entire process. However, the controller 110 preferably adjusts the cycling speed for each cycle according to the data received by the web sensor 84 and the tool sensor 120 to re-register the web 20 with the tool at each web section to be processed, while maintaining a constant mean speed of rotation for the second drive roll motor 114 . The re-register allows corrections in register to be made upstream of the web processing, rather than conventional register done on measurements taken downstream of processing, i.e. after the web is processed in a misaligned manner and as such unusable. The re-register thus allow for a reduction in waste material.
[0040] In cases when the length of an individual section of the web 20 to be processed is equal to the circumference of the tool cylinder 78 , i.e. the tool covers the entire diameter of the tool cylinder 78 , the controller 110 can instruct the second drive roll motor 114 to rotate at a constant speed, and the web processing assembly 12 performs in a rotary manner. Preferably, the second drive roll motor 114 rotates at a cycling speed including a period of variable speed to re-register the web 20 with the tool upon receiving data from the web and tool sensors 84 , 120 . It is understood that the order of magnitude of the speed variation in this case will be significantly less than in the true semi-rotary process described above.
[0041] The controller 110 can also receive a feedback signal from the tension maintenance system 122 . The tension maintenance system 122 includes a first feedback device 124 monitoring the reciprocating movement of the first idler roller 62 , and a second feedback device 126 monitoring the reciprocating movement of the second idler roller 70 . The first and second feedback devices 124 , 126 are preferably respectively located at the first and second pivots 60 , 68 of the first and second set of arms 56 , 64 (see FIG. 1 ). Upon adjustment of the pneumatic cylinder 76 to adjust the tension of the web 20 , the mean position of the reciprocating motion of the two idler rollers 62 , 70 will move away from a home position. For example, augmenting the pressure of the cylinder 76 will augment the web tension 20 and move the arms 56 , 64 downwardly, such that the mean position of the reciprocating motion of the two idler rollers 62 , 70 will drift down from its home position. The feedback devices 124 , 126 each send a signal to the controller 110 if such a change in the mean position of its respective idler roller 62 , 70 occurs.
[0042] In the absence of a signal from the feedback devices 124 , 126 , the controller 110 sets the speed of the second drive roll motor 114 so that the second drive roll 40 drives the web 20 at a mean speed equal to the constant speed of the web 20 at the first drive roll 32 . The controller also sets the speed of the third drive roll motor 116 such that the third drive roll 46 drives the web 20 at a constant speed equal to the constant speed of the web 20 at the first drive roll 32 . The mean speed of the web 20 throughout the entire web processing assembly 12 will be equal to the constant speed of the web 20 at the first and third drive rolls 32 , 46 . The controller 110 preferably sets the ratio between the mean speed of the web 20 and the constant tangential speed of the anvil cylinder motor 118 (and as such the constant tangential speed of the tool cylinder 78 ) to be proportional to a ratio between the length of an individual section of the web 20 to be processed and the circumference of the tool cylinder 78 . Preferably, the two ratios are equal, such that, for example, when the circumference of the tool cylinder 78 is double the length of an individual section of the web 20 , the tangential speed of the tool cylinder 78 is double the mean speed of the web 20 . When the circumference of the tool cylinder 78 and the length of an individual section of the web 20 are equal, the tangential speed of the tool cylinder 78 is equal to the mean speed of the web 20 , and the web 20 is processed in a rotary manner.
[0043] When a signal from the first feedback device 124 is received, indicating a change in center position of the first idler roller 62 , the controller 110 increments the speed of all the motors downstream to compensate for this change in center position until the center position of the reciprocating motion of the first idler roller 62 is back to its home position according to the first feedback device 124 . Thus, the mean speed of the second drive roll motor 114 , as well as the constant speed of the third drive roll motor 116 and of the anvil cylinder motor 118 are equally incremented. If a signal from the second feedback device 126 is received, indicating a change in center position of the second idler roller 70 , the controller 110 increments the speed of the motor downstream, i.e. the speed of the third drive roll motor 116 , until the center position of the reciprocating motion of the second idler roller 70 is back to its home position according to the second feedback device 126 .
[0044] In use, as illustrated in FIG. 4 with reference to the preceding Figures, the web 20 passes through the web processing module 10 according to the following: first, a user 130 provides data to the controller 110 on the process to be performed, e.g. ratio of the length of individual sections of the web with respect to the circumference of the tool cylinder, constant speed of the web 20 at the first cassette 30 or speed of rotation of the tool cylinder 78 , etc., as indicated at 154 . The controller 110 then computes the profile for the process, including the cycling speed at the second cassette 38 , as indicated at 156 . The controller 110 performs a reset on the position of the web 20 , tool, and first and second idler rollers 62 , 70 , by slowly moving the web 20 according to data received by the web and tool sensors 84 , 120 as well as the first and second feedback devices 124 , 126 , as indicated at 158 .
[0045] The web 20 can now be processed. The web 20 is pulled from the unwind roll 16 at a constant speed by the first drive roll 32 , as indicated at 160 . The web 20 travels at constant speed to the first idler roller 62 . The center position A of the first idler roller 62 is detected by the first feedback device 124 , as indicated at 162 . The position B of the section of the web 20 near the tool cylinder 78 is detected by the web sensor 84 and the position C of the tool is detected by the tool sensor 120 , as indicated respectively at 164 and 166 . The controller 110 adjusts the cycling speed of the second drive roll motor 114 according to the tool and web section positions B and C to perform a re-register of the web 20 with the tool, and the mean cycling speed according to the first idler roller position A, as indicated at 168 . The web 20 is pulled at the cycling speed by the second drive roll 40 , as indicated in 170 . The speed of the anvil cylinder 80 is adjusted by the controller 110 according to the first idler roller position A, see 172 , and the web 20 is processed by the tool, as indicated at 174 . The web 20 travels at cycling speed to the second idler roller 70 . The center position D of the second idler roller 70 is detected by the second feedback device 126 , as indicated at 176 . The constant speed of the third drive roll motor 116 is adjusted by the controller 110 according to the first idler roller position A and the second idler roller position D, as indicated at 178 . The web 20 is pulled at the constant speed by the third drive roll 46 , as indicated at 180 . of course, since the web 20 is continuous, all the above-described operations are done simultaneously, but were described here following the progression of a reference point of the web 20 for ease of understanding.
[0046] The web processing module 10 can be used in series with other similar modules 11 . A series of two modules 10 , 11 is illustrated in FIG. 2 . The rewind roll 24 for the web 20 is placed downstream of the second module 11 . The second module is similar in construction to the first module 10 , and as such will not be detailed here. The components of the second module 11 are represented by a reference numeral corresponding to the reference numeral of the corresponding component in the first module 10 , augmented by 200 . The drive rolls of the second module 11 are referred to as fourth, fifth and sixth drive rolls 232 , 240 , 246 ; the idler rollers, as third and fourth idler rollers 262 , 270 ; the feedback devices, as third and fourth feedback devices 324 , 326 , etc.
[0047] The controller 310 of the second module 12 is in communication and synchronized with the controller 110 of the first module 110 . Alternatively, a single controller can be used for both modules 10 , 11 .
[0048] When the module 10 is used in series with the similar module 11 , the third cassette 44 is preferably inactive, i.e. it does not drive the web and acts as an idler. Alternatively, the fourth cassette 230 can be inactive instead of the third cassette 44 .
[0049] Before circulating the web through the first or second modules 11 , 12 , the user 130 also provides data to the controller 310 of the second module on the process to be performed, as indicated at 155 . The controller 310 then computes the profile for the process as indicated at 157 . The controller 310 performs a reset on the position of the web 20 , tool, and first and second idler rollers 262 , 270 , by slowly moving the web 20 as indicated at 159 . The web 20 is circulated through the first module 11 , as indicated at 161 and as described above, except with steps 178 and 180 being omitted since in this case the third cassette 44 is inactive.
[0050] The web 20 then circulates through the module 11 according to the following: first, the web 20 is pulled from the first module 10 at a constant speed by the fourth drive roll 232 , as indicated at 182 , and travels at constant speed to the third idler roller 262 . The center position E of the third idler roller 262 is detected by the third feedback device 324 , as indicated at 184 . The position F of the section of the web 20 near the tool cylinder 278 is detected by the web sensor 284 and the position G of the tool is detected by the tool sensor 320 , as indicated respectively at 186 and 188 . The controller 110 adjusts the cycling speed of the fifth drive roll motor 314 according to the tool and web section positions F and G to perform a re-register of the web 20 with the tool, and the mean cycling speed according to the first idler roller position A, the second idler roller position D and the third idler roller position E, as indicated at 190 . The web 20 is pulled at the cycling speed by the fifth drive roll 240 , as indicated in 192 . The speed of the anvil cylinder 280 is adjusted by the controller 110 according to the first idler roller position A, the second idler roller position D and the third idler roller position E, see 194 , and the web 20 is processed by the tool, as indicated at 196 . The web 20 travels at cycling speed to the fourth idler roller 270 . The center position H of the fourth idler roller 270 is detected by the fourth feedback device 326 , as indicated at 198 . The constant speed of the sixth drive roll motor 316 is adjusted by the controller 110 according to the first idler roller position A, the second idler roller position D, the third idler roller position E and the fourth idler roller position H, as indicated at 200 . The web 20 is pulled at the constant speed by the sixth drive roll 246 , as indicated at 202 .
[0051] The tension in the web 20 can be advantageously adjusted to a different value in each module 10 , 11 , since the first module 10 is isolated in tension from the second module 11 by the third or fourth cassette 44 , 230 . The modules 10 , 11 can also be used in a standard rotary manner, with the second and fifth drive rolls 40 , 240 pulling the web at a constant speed. As such, a plurality of modules such as 10 and 11 can be installed in series to perform multiple processes on a web, whether rotary or semi-rotary, each process being independent in tension from the others. The symmetry of the module 10 also allows for easily reversing of the direction of travel of the web 20 if another configuration is required.
[0052] The re-register step performed for each section also allows two modules such as 10 , 11 to be used independently, i.e. without having the web 20 run directly from one another, for a same web. For example, the first module 10 could print in each section of the web 20 , and the second module 11 could die cut in each section, while easily registering the previously printed sections with the die.
[0053] Since the web 20 exiting the web processing module 10 is tension isolated and has an independent re-register, the module 10 can also be used in series with any number of rotating web processing machines.
[0054] A conveyor can also be located just downstream of the tool cylinder 78 in cases when the tool cylinder 78 is a cutting cylinder performing through cut or sheeting, such as to convey the cut elements of the web 20 . In the case of through cut with matrix, the waste matrix passes through the second dancer assembly 54 , through the third cassette 44 , and is rewound on the rewind roll 24 . In the case of sheeting, i.e. the web 20 is completely cut at each section, the second dancer assembly 54 is not used since there is no more web after the sheeting step is performed, and as such the second arm 64 is locked in place. The cut sheets are conveyed by the conveyor from the tool cylinder 78 .
[0055] Other units, such as an infrared and/or ultraviolet drying unit, can be provided within the module 10 downstream of the tool cylinder 78 , or in series with the module 10 .
[0056] As mentioned above, the module 10 can thus easily be configured, by placing an appropriate tool plate around the tool cylinder 78 , to perform multiple operations such as, but not limited to, die cutting, laminating, printing, coating, slitting, underscoring, perforating, etc. The tool cylinder 78 can also include more than one tool along its circumference, with the web 20 being “backed up” between each tool by the second cassette 38 . In that case, the relation between the speed of the tool cylinder 78 and of the web 20 is adjusted accordingly. One example would be two separate perpendicular cutting dies, which would act on a same location on the section of the web 20 to perform a cross-shaped cut.
[0057] The embodiments of the invention described above are intended to be exemplary. Those skilled in the art will therefore appreciate that the foregoing description is illustrative only, and that various alternatives and modifications can be devised without departing from the spirit of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. | A web processing assembly including first, second and third fixed spaced apart pairs of nip rollers moving the web respectively at a first, second and third speeds, the first and third speeds being constant and similar, the second speed being variable with a mean speed similar to the first and third speeds, a first idler roller engaging the web between the first and second pair of rollers and a second idler roller engaging the web between the second and third pair of rollers, each idler roller maintaining the web in constant tension by moving along a restrained path perpendicular to its axis to compensate for a difference between the variable second speed and the respective one of the constant first and third speeds. A method for processing a web and system for conveying a web are also disclosed. | 8 |
FIELD OF THE INVENTION
This invention is directed towards an improved method and apparatus for securing and stabilizing a lightweight collapsible building structure adapted for the provision of being a controlled environment along a moving work site. I have found the need to provide a simple and efficient method of securing and stabilizing a protective environment along a moving work site such as the construction of a pipeline in areas where the weather conditions substantially interfere with outdoor construction. More particularly my invention is directed towards an improved means for stabilizing a lightweight, transportable collapsible structure against high winds caused by adverse weather conditions or excessive lift forces resulting from the superatmospheric condition maintained within the structure.
BACKGROUND OF THE INVENTION
My invention is an improvement in the manner of stabilizing and securing a controlled movable environment as disclosed in my prior U.S. Pat. No. 3,990,532 entitled "Method and Apparatus for Providing a Controlled Movable Environment" which issued Nov. 9, 1976. Construction of major commercial and industrial complexes can be seriously hampered by adverse weather conditions. The time loss can be a significant cost factor to a contractor. In several hostile weather regions of the world estimated construction time of a project is forecast based on prior recorded seasonal weather conditions. It is, therefore, highly desirable to have available a sheltered environment which can be easily and rapidly assembled. In addition, the sheltered environment can be relied on by the contractor in forecasting his construction schedule. Of all outdoor construction activity, pipeline installation, due to its continuously moving nature, appears most in need of a controlled environment which can be moved easily along the work site.
In the past, pipeline construction has been hampered by adverse weather conditions. Traditional practice has been to either construct the pipeline in the open environment or within a temporary type shelter which is then moved along the moving work site as progress continues being torn down and reerected at successive locations. While these practices exhibit some utility, the petroleum and construction industries have always felt that there was a definite need for significant advancement. Such an advancement has been provided for in my prior U.S. Pat. No. 3,990,532. A further improvement is now provided according to the present invention wherein the procedure of securing and stabilizing a lightweight collapsible structure for a controlled environment that is being moved along a moving work site is significantly improved thereby enhancing its mobile characteristic.
SUMMARY OF MY INVENTION
My invention is an improved method and apparatus of securing and stabilizing a lightweight collapsible structure as a controlled environment when displaced along a moving work site. I hereby incorporate by reference my prior U.S. Pat. No. 3,990,532 entitled "Method and Apparatus for Providing a Controlled Moveable Environment" issued Nov. 9, 1976 and all related references cited therein. In that patent I disclose an enclosed moveable environment capable of providing a controlled working condition free from the effects of adverse weather and chiefly comprised of a lightweight collapsible building structure attached to elongated platforms which run along the length of the lightweight structure. The structure is fabricated of thin flexible air impervious material and is maintained in an erected position by blowers or fans which supply air pressure in a regulated manner into the interior of the structure thereby creating a superatmospheric condition. Alternatively, the lightweight structure may be composed of a series of flexible tubular elements which are maintained in an inflated position by the same fans or blowers; however as disclosed in my prior patent, with the alternative method of fabrication the interior of the lightweight structure is at atmospheric pressure. The tubular elements are maintained under a superatmospheric condition. The structure may be constructed of both an impervious flexible material and tubular elements. The structure is advanced forward along the moving work site by a tractor tow device or it may be equipped to be self-propelled by mounting a motor directly on the platform engaging a series of low pressure tires below the platform. In order to reduce the effect of excessive wind forces on the structure and to permit passage through limited spaces, I have taught in my prior patent, a way to adjust the height-to-width ratio of the light-weight structure.
According to the present invention, the improvement is provided which comprises, in the first instance, providing a pair of anchor tracks, each on opposite sides of the work site and extending at least along the entire length of the light-weight building structure in a path generally parallel to the direction of anticipated movement of the controlled environment. These anchor tracks may comprise, for example, a series of augers, each having an appropriate connecting means, such as a hook, an eye of the like, at its head, which have been anchored into the ground along at least a portion of the anticipated length of the moving work site. In another embodiment, a horizontal, generally ground level, cable is securely anchored at predetermined intervals to the ground along opposite sides of the moving work site external to the lightweight building structure. As will be apparent to those skilled in the art, a combination of the cables and the ground augers referred to above may be utilized.
A plurality of stabilizng cables, hereinafter referred to sometimes a "stability lines" are secured to the structure of the controlled environment at suitable points positioned around the periphery of the controlled environment, or at least generally along the length of either side thereof. These stability lines, which may be nothing more than suitable lengths of rope or some other flexible, but strong, material are releasably attached to the anchor track in a manner so as to hold the structure of the controlled environment stable against the effect of excessive wind forces while at the same time being capable of moving along the anchor track with the controlled environment when it is desired to advance the controlled environment along the moving work site. In one preferred embodiment of the invention, the stability lines are also releasably attached to a cable or track means which is horizontally mounted along the outside of the platforms of the controlled environment structure in a manner such that some lateral movement may be permitted when that is desirable. In another embodiment the stability lines may consist essentially of a hook, which attaches to the anchor track, a connection mount to fasten the line to the platform, and a flexible line long enough to extend to the anchor track but remains somewhat taut. The hook may be of a J-shaped configuration or, as an alternate embodiment, a pulley block/sheave arrangement which reduces the frictional drag force between the cable and stability lines.
As will be apparent, to those skilled in the art, the stability lines may be attached to any reasonable point on the controlled environment structure, as for example the platform, the lightweight structure, or a cable which is mounted between the platforms on each side of the structure. The stability lines would still perform the same function as discussed above by attaching to the horizontal cable which is fastened to the augers regardless of where the stability lines were mounted. In calm weather conditions and with low superatmospheric pressure within the collapsible building, the structure may be advanced along the work site without a need for stabilizing it to the horizontal cable. If satisfactory operating conditions continue, the horizontal cable need not even be employed. When higher winds do approach, however, the operation can halt and the structure can be securely stabilized to the ground by attaching the stability lines directly to the pre-set augers which are located along both sides of the moving work site. Alternatively, the horizontal cables may be used in which case the operation may continue even under higher winds by securing the stability lines to the horizontal cables and allowing the stability lines to advance along the horizontal cables which are secured to the ground by the augers as the controlled environment structure advances along the moving work site.
The advancement of the stability lines along the anchor tracks as a means of providing stability is a unique feature of my invention. In addition, the entire advancement of the cables at periodic intervals as the structure approaches the end of the cables is another unique feature of my invention.
Therefore, it is a primary objective of my present invention to provide an efficient, simple, and safe method of stabilizing a lightweight, collapsible building structure used as a controlled environment as it moves along a moving work site.
It is another object of my present invention to provide an apparatus for securing and stabilizing a lightweight collapsible building structure used as a controlled environment as it moves along a moving work site.
Examples of the more important features of my invention have been summarized rather broadly in order that the detailed description that follows may be better understood and in order that the contribution to the art may be better appreciated. There are of course additional features of my invention that will be described hereafter and which will also form the subject of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the recited features, advantages, and objectives in my invention as well as others, which will become apparent, are obtained and can be understood in detail, a better description of my invention briefly summarized above, may be had by a reference to the embodiments which are illustrated in the appended drawings and form a part of my specification.
It shall be noted that the appended drawings are not to be considered limiting the scope of my invention for my invention may admit to other equally effective embodiments without departing from its spirit and scope.
In the Drawings
FIG. 1 depicts an isometric view of the lightweight collapsible controlled environment structure in an inflated position being towed by a tractor tow means. Also shown is my present invention comprising anchor tracks straddling each side of the moving work site which connect with the stability lines stabilizing the structure.
FIG. 2 is a detail of the stability line connected to the platform and the cable. FIG. 2a is a detail of the hook means attaching the stability line to the cable. In the preferred embodiment the hook means comprises a J-shaped element which loops around the cable.
FIG. 3 is a detail of my alternate embodiment depicting a hook means comprising a pulley housing/sheave arrangement.
FIG. 4 is a detail of the auger device shown securely anchored to the ground and attached to the cable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As introductory to a detail description of my present invention, several points should be made in view of my prior invention to exemplify the significance of my present invention. With respect to FIGS. 1 and 4 of my prior patent, the controlled environment is maintained in an erect position by a superatmospheric condition. To provide such a condition, air supply means, located on the platform, blows air into the lightweight structure keeping it in an erect attitude. A motor means drives a fan or blower discharging air into the interior of the structure. In my prior patent I also disclosed a pressure system whereby air from the motor means can be routed below each platform or sled by closing a valve forcing air under pressure between the sled and the ground surface, thereby suspending the sled off the ground. The sled is circumscribed by an apron which encloses a plurality of adjacent flexible fingers. The apron and adjustable flexible fingers assist in providing an effective air seal preventing a loss of pressure from the cushion of air. In this manner, the entire controlled environment can be moved horizontally along the work site with a minimal amount of pulling force. To stabilize the structure during adverse weather, or alternatively when the air pressure inside the structure causes a sufficient lift force to render the overall system unstable I disclosed and claimed a method wherein the direction of the blowers or fans mounted on the platform are reversed. Rather than providing a cushion of air, the reversal of the blowers results in a suction between the ground and the platform or sled. Consequently with the additional hold-down force available from the suction, the stability of the structure and platform is improved. My present invention is an improvement on stabilizing the controlled environment structure without the need of providing a suction.
Referring first to FIG. 1, there is depicted lightweight collapsible controlled environment structure 1 under tow by motive means 2. The controlled environment structure is advanced by similar motive means as disclosed in FIGS. 1 and 2 of my prior patent. A tractor towing device may be used to pull the structure, or the controlled environment structure may be equipped with self-propelling drive motors mounted on the platform. Low pressure tires are mounted on axles and secured within the platform providing a guide means and preventing laterial movement of the structure. The tires also provide a means of driving the structure if designed to be self-propelled. Alternatively, a plurality of keels may be used to prevent lateral drift of the structure rather than the use of the low pressure tires as shown in FIG. 7 of my prior patent. Turning back to FIG. 1 herein, air supply means 3, mounted on platform 4, keeps controlled environment structure 1, hereinafter referred to as "structure", erect. A perimeter apron 5 circumscribes structure 1 providing a seal between structure 1 and the contour of ground 8 thereby preventing a loss of air pressure. Also shown in FIG. 1 is my improved method of securing and stabilizing structure 1 under tow. Cables 6 and augers 9 are located adjacent both sides of moving work site 7. A cable 6 is located on each side of moving work site 7 and is anchored to ground 8 by augers 9. Augers 9 are connected to cable 6 by catch 10. Stability lines 11 are attached to platform 4 by connection mount 12 at periodic intervals along the length of structure 1. Lines 11 stabilize structure 1 by attaching to cable 6 via hook means 13.
With reference to FIGS. 2 and 2a, line 11 is attached to platform 4 by connecton mount 12. Line 11 attaches to hook means 13. In my preferred embodiment hook means 13 is a J-shaped member which loops around cable 6 to properly secure and stabilize structure 1. FIG. 2a illustrates in greater detail hook means 13. Due to its J-shaped, hook means 13 easily attaches around cable 6. Under severe wind conditions stability line 11 secures structure 1 by exerting a tension force on cable 6 through hook means 13. A plurality of hook means 13 would attach to cables 6 along both sides of structure 1. It will be apparent that the laterial forces exerted on structure 1 from adverse weather conditions or vertical lift forces resulting from the superatmospheric pressure condition within structure 1 are overcome by stability lines 11 securely attached to cables 6.
With respect to FIG. 3, an alternating embodiment of my hook means 13 is depicted which comprises pulley housing 14 and sheave 15. Sheave 15 is maintained in position by quick-disconnect pin 16. Pulley housing 14 is attached to line 11 by ring 17. Cable 6 rolls on sheave 15 as structure 1 advances along moving site 7. In this manner, virtually no friction is generated between hook means 13 and cable 6 thereby insuring that stability lines 11 will not drag on cable 6 during the forward movement of structure 1.
Turning to FIG. 4, auger 9 is shown in place securely anchored within ground 8. The pitch and root dimensions of vane 19 are standard within the industry. Catch 10 is attached to the upper end 20 of auger 9. Catch 10 remains above the surface of ground 8 after placement of auger 9. Cable 6 is fastened to ground 8 by engaging cable 6 within catch 10. Catch 10 comprises a J-shaped element with long side 21 towards structure 1. In this manner, any increase in the tension force from stability line 11 will not dislocate cable 6 from catch 10.
In the actual operation cables 6 are about 1 inch in diameter and are stretched out one or two miles adjacent the right-of-way of the moving work slight. The cables are parallel to one other and the moving work site. Each cable is secured at its ends, as for example by an auger. Alternatively, the cable may be kept taut by attaching one or both ends to a tractor or bulldozer. It is also anchored at predetermined intervals along its length, in most cases about every 10-50 feet in my invention, by additional augers. As will be appreciated, the actual interval will be a function of the internal air pressure of the structure, the wind velocities, the contour of the terrain, and related environmental and surface geological conditions. Cables 6 are spaced 10 to 15 feet further apart than the total width of the lightweight structure and platforms. Stability lines 11 are about one-half inch in diameter and spaced every 10-30 feet along the length of both sides of the lightweight structure.
Since the right-of-way of a moving work site is well known in advance of construction, the augers may be placed in presurveyed positions months in advance of the construction. This may be necessary in certain environmental conditions. For example, in locations where the ground surface is frozen for months out of the year the augers would be installed during the warmer months when the required "drilling-in" of the auger to properly anchor it is possible. Frozen ground is very difficult to drill in; yet, it is far more efficient to move heavy equipment for pipeline construction over frozen ground than it is to move the same equipment over thawed ground in warm weather.
After the augers are anchored and the cable secured within the catches, the lightweight structure is inflated and stabilized by the stability lines. The cable is not connected to those augers immediately adjacent the structure in order that the hook means of these stability lines will not interfere with the catch of each auger as the structure advances. In addition, the cable is not connected to those augers that are 100-200 feet in advance of the structure to allow for the forward movement of the structure without interference between the the stability lines and augers. As the structure passes an unhooked auger the cable is easily looped around the auger and secured within its catch. In this manner, the stability of the structure is maintained with a minimal amount of unhooked augers. If for some reason the directional movement of the structure must be reversed, the length of the cable immediately behind the structure is unhooked from those augers and the length of cable forward of the structure hooked. The structure can then be towed in reverse with the improved stability of my invention.
If the cables are anchored at each end to bulldozers, then the entire length of each cable is also advanced as the light-weight structure approaches the end of the cables thereby requiring only one set of cables to perform the task of stabilizing the structure during the construction operation. As the front bulldozer advances each cable and passes an auger, the cable is looped around it properly securing the cable. In a similar manner, the cable is released from each auger as the rear bulldozer approaches. The required clearance between the the center of the bulldozer and the top of the catch is predetermined to ensure that the catch is not damaged during passage of the bulldozer. Alternatively, the auger may be anchored deeper into the ground to ensure an adequate clearance.
With my alternate embodiment, the pulley housing/sheave arrangement need only be connected one time since each auger is released from the cable as the stability lines advance with the structure. The sheave reduces the frictional force between the hook means and cable consequently reducing the drag force. Depending on the number of stability lines connected to the cables, the drag force may become a factor impeding the free movement of the structure. In that case, the use of my alternate embodiment would enhance the value of my invention.
I recognize that a more sophisticated pulley housing/sheave arrangement may be developed from my alternate disclosure as illustrated in FIG. 3. A "Ski-Lift" type block may be incorporated into my invention which would not require that the cable be released from the augers immediately adjacent the structure in order to avoid an interference between the stability lines and the augers.
My invention securely stabilizes a controlled moveable environment as claimed in my U.S. Pat. No. 3,990,532 when towed or self-propelled along a moving work site. The light-weight structure is securely anchored to the ground enhancing its ability to resist wind forces which might otherwise blow the structure down. In addition, the structure is able to withstand greater lift forces resulting from the superatmospheric pressure. The advancement of the stability lines along the cable is a unique means of securing and stabilizing the structure. More particularly, the periodic advancement of the cables as the structure reaches their ends is another unique feature of my invention.
Thus, it is apparent that there has been provided, in accordance with the invention, an improved method and apparatus of securing and stabilizing a lightweight collapsible structure used as a controlled environment along a moving work site. Based on the above description it is apparent that my invention substantially satisfies the objectives and advantages set forth above. Although the present invention has been described in conjunction with specific forms thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing disclosure. Accordingly, it is intended that all such alternatives, modifications, and variations which fall within the scope of the invention as defined in the appended claims be embraced thereby. | Method and apparatus for securing and stabilizing a lightweight collapsible structure that is moving along a moving work site. Anchor tracks are securely anchored along each side of a moving work site. Stability lines connected to the platform of the lightweight structure connect with the anchor tracks. In this manner the structure is more stable and less susceptable to damage due to adverse weather conditions or lift forces caused by the superatmospheric condition resulting from the pressure differential needed to maintain the lightweight structure in an erect position. | 4 |
The Invention relates to a process for the filtration of polymer melts using filter cartridges and is a division of Ser. No. 08/252,753 filed Jun. 2, 1994, now allowed and pending issue.
BACKGROUND OF THE INVENTION
Increasing requirements on the quality of polymer products, such as fibers, foils, but also pellets from linear polyesters, polycarbonates, polyamides or polyolefines, demand the finest possible filtration of the polymer melts after discharge from the last synthesis reactor or separator, and before the entrance into the spinning unit for further processing.
THE PRIOR ART
Cylindrical filter elements, so-called "filter cartridges" of folded, flexible materials, such as metal wire webbing and non-woven metallic fiber fabric, with a filter fineness--depending on the intended use of the polymer--of 5 to 150 μm currently are used for this filtration. The final drop in pressure of the filter cartridges, depending on the order of magnitude, ranges from 50 to 150 bar. The throughput of large-scale technical apparatuses requires a multiplicity of filter cartridges which are held in a filter plate, and are grouped together into filter packets. The filter packets are inserted in vessels which are pressure-tight, and are thus correspondingly thick-walled. The polymer melt which is to be filtered is pumped into the pressure vessel and, after passing through the porous walls of the filter cartridges, exits again at the filter plate. In order to maintain the melt temperature of over 180° C. to approx. 350° C., depending on the polymer, the pressure vessel is inserted, in a precisely fitting manner, into a second vessel, the walls of which have heat exchanger fluid flowing through them (see: Chemiefasern / Textilindustrie [November 1989], pages 1771-74, as well as Filtration & Separation, Volume 26/1 [January/February 1989], pages 43-45).
The high quality demands on polymer products at the present time, particularly during direct spinning, during the filtration stage, presuppose a uniform residence time of the entire polymer melt, or a uniform through-flow without dead zones, as well as a uniform, constantly even temperature.
In the known polymer melt filtration systems previously described, a uniform throughflow is not guaranteed since the drops in pressure from the filter cartridges, and the distances between the filter cartridges and the adjacent wall are different from one cartridge to the next. In particular, the flow is minimal directly below the filter plate which results in thermal damage to the polymer, even to the point of cracked products. The primary flow can be influenced through the installation of guide surfaces, but not the dead zones, however, which are, instead, increased.
Also, a uniform tempering of the entire melt in the known systems is problematic, since the heat transfer is impeded by the thick walls of the pressure vessel and, in addition, by the small clearance between the pressure vessel and the heating vessel, which is irregular over its circumference. Differing temperatures which, among other points, bring about differences in the viscosity and consequently in the residence time of the polymer, arise between the center of the vessel and the walls of the vessel, as well as along the wall. Increases in temperature, which are produced by pressure differences in the melt, can be compensated for only in an insufficient manner.
It is additionally known to control the temperature of the polymer in the processing unit, independently of the temperature of the last synthesis reactor, by interpositioning an additional heat exchanger, such as a pipe assembly heat exchanger, for example.
SUMMARY OF THE INVENTION
It is thus the object of the invention to modify the known process for polymer melt filtration in such a manner that the disadvantages noted above are obviated, or at least minimized.
The invention provides a process which is economical and ensures a uniform residence time without dead zones, as well as a uniform, targeted tempering of the polymer melt. The apparatus of the invention is designed to facilitate performance of the process.
In a preferred form of the invention, the filter comprises a cylindrical vessel divided by two horizontal plates into a small upper collecting chamber, a large middle chamber and a small lower product-distribution chamber. A plurality of vertical open ended heat exchange pipes are mounted in the middle chamber and extend between the plates. The space between the pipes connects to a source of heat carrier fluid for heating the polymer flowing through the filter pipes. A filter cartridge is disposed concentrically within each pipe and is radially spaced therefrom by a projection on the inner wall of the pipe to form an annular space around each cartridge. Each cartridge is closed at its lower ends and open at its upper end which connects to the upper collecting chamber within the vessel. A plurality of narrow channels are circumferentially spaced around the top end of the cartridge between the top end and the projection on the inner wall of the pipe to provide fluid communication between the annular space and the collecting chamber. A small amount of polymer flowing through these channels minimizes the generation of dead zones inside the annular space. Most of the polymer flows radially from the annular space, through the wall of the cartridge filter and out the open end thereof into the collecting chamber where it joins the polymer discharged from said channels. About 0.03 to 3.0 weight % of the polymer stream flows through the channels.
The individual cartridges are removable from the pipes for changing and cleaning. Thus, it is not necessary to cool down the whole apparatus to remove the entire filter assembly within the cylindrical vessel. Also, it is preferred that the channels are oriented radially toward the periphery of the pipes and are equipped with a filter medium.
The temperature at which the polymer is discharged is different from or substantially equal to the temperature at which the polymer enters the filter. By eliminating the dead zones and by providing a uniform, targeted tempering, the residence time of the polymer within the filter is uniform.
THE DRAWING
The invention will be illustrated in greater detail with reference to the sole FIGURE which schematically depicts a longitudinal section through one half of a preferred form of implementation of the filtration apparatus which is used in the process in accordance with the invention. To make visible the inventive details, instead of the multitude of filter cartridges actually present in the filter, only two filter cartridges with greatly enlarged diameter (compared with the other dimensions) are shown.
DETAILED DESCRIPTION
The polymer filtration apparatus used to practice the process of the invention comprises essentially a closed upright cylindrical vessel 3 divided into three separated compartments or chambers by two horizontal partitioning walls, usually called pipe plates 7a, 7b. The middle compartment is much larger than the two other chambers 11, 12 and contains a plurality of vertical open-ended pipes 4a, the opposed ends of which are inserted in and held by borings in the pipe plates 7a, 7b. Horizontal sequential disk baffles 3c also serve to position the pipes within the cylindrical vessel 3. A heat carrying fluid enters the middle chamber through the tube 3a near lower pipe plate 7a and surrounds all the pipes 4a. The flow is oriented by the baffles 3c and exits through tube 3b close to the upper pipe plate 7b.
The polymer melt is pumped from below through a central opening 1 in the lower cover 2 of the vessel into the lower product-distribution chamber 12 and then into the pipes 4a which are circumcirculated by heat carrying fluid. The lower chamber 12 between the lower vessel cover or bottom 2 and the lower pipe plate 7a should be formed in such a manner to ensure uniform distribution of the melt to all pipes in the vessel.
In divergence from conventional pipe assembly heat exchangers, a filter cartridge 4c with a ring connection 4b on the upper end is inserted concentrically into every pipe 4a with the formation of an external annular space or aperture 8. The upper end of pipe 4a has a projection 13 which serves to space the cartridge from the inner wall of the pipe. Filter cartridges of the commercially conventional type, such as those made from folded metal wire lattice with an insert of folded non-woven metallic fiber fabric, for example, can be used. The filter cartridges 4c should extend close to the lower end of the heat exchanger pipes 4a in the range of from 95 to 100% of the length of the pipe. The lower ends of the cartridges are closed. The external diameter of the filter cartridges 4c is constant over its entire length, so that the annular aperture 8 has a constant width between the filter cartridge 4c and the surrounding pipe 4a. The width of the space 8 is dimensioned in a manner to minimize the loss of pressure which is caused by the annular aperture in relation to that which is caused by the filter medium 4c. Depending on the diameter of the filter cartridges, the width of the aperture is from 5 to 20 mm.
Filter cartridges 4c having diameters which reduce slightly in the downward direction may be used. In this case, the width of the space 8 correspondingly increases in the downward direction. By providing an annular space of defined width, constant flow conditions which are equal for all filter cartridges are achieved.
The upper ends of the filter cartridges 4c connect to an externally threaded connecting fitting 4b which screws into internal threads on the projection 13 of pipe 4a. Instead of a screw thread, the connection between the fitting 4b of the filter cartridges 4c and the heat exchanger pipes 4a can also be carried out in other ways, for example, in a bayonet-like manner. But since the filter cartridges 4c must be removed frequently for cleaning, they must be easily detachable. Preferably, the connection ring fittings 4b are of larger diameter in the upper edge area to provide a flange 4f extending over the ends of the heat exchanger pipes 4a. The fittings are provided with an annular washer between flange 4f and the upper side of pipe plate 7b or the upper ends of the pipes 4a as explained below. Centering supports 4d, such as three pins or clamps symmetrically arranged, can additionally be provided in the lower pipe area.
At the level of the connecting ring fittings 4b several narrow connection channels 9a, connecting the annular space 8 and the upper collecting chamber 11, are disposed in circumferentially-spaced relation between each pipe projection 13 and the ring fitting 4b inserted therein. These channels are preferably constructed as grooves or borings in the ring fittings 4b, but can also be positioned entirely or partially within the wall of projection 13 on the pipe 4a. Preferably, the channels 9a in the area of the flange 4f turn laterally in a direction parallel to the pipe plate 7b as indicated at 9b. The channels 9a, 9b may contain a filter medium, preferably a non-woven metallic fiber fabric or a porous metal. The annular washer mentioned above is preferably constructed as a porous filter 9d; the filter medium can also fill the entire channel 9c, in particular when the washer consists of a non-porous seal with passages for channels 9b.
Most of the melt entering the inlet 1 flows through the wall of cartridge 4c as indicated by the arrows, and exits in the axial area of the cartridges as a primary stream at 10a. A minor proportion, comprising a secondary stream 10b, flows directly through annular spaces into channels 9a, 9b and exits in the peripheral area of the cartridges.
The cross-section of these channels 9a, 9b is dimensioned in such a manner that the flow therethrough constitutes approximately 0.03 to 3.0 weight %, preferably 0.1 to 1.0 weight % of the entire stream. The quantity of secondary stream 10b is so small that filtering of this portion of polymer melt is not absolutely necessary. Preferably, however, filtering is provided by filter medium 9c, 9d in the channels.
The primary and secondary streams 10a, 10b exiting from the heat exchanger pipes 4a are united in a collecting chamber 11 beneath the upper cover 5 of the vessel 3. The filtered polymer melt is finally discharged through a central discharge opening 6 from the collecting chamber.
The collecting chamber 11 may include deflecting plates, not shown, which deflect the streams 10a, 10b exiting from the pipes before reaching the discharge opening 6 in the direction of the periphery of the collecting chamber 11. This measure leads to a more uniform through-flow of all spaces in the collecting chamber.
The secondary melt streams 10b impede the occurrence of dead zones with stagnating polymer melt. Thus, polymer melt flows continuously through the upper annular aperture area and within the collecting chamber 11 at the circumference of the connecting fittings 4b.
In order to prevent low-current flow zones in the collecting chamber 11 in the area between the pipes 4a, the pipes are positioned in the densest packing geometrically possible, but spaced sufficiently for the circumcirculation of heat carrier fluid. This arrangement makes possible a rinsing of the spaces between the pipes by means of the secondary melt streams 10b.
The temperature of the polymer melt which is to be filtered lies, in general, 10° to 50° C. above the melt temperature of the polymer and thus, depending on the polymer, at approximately 180° C. to over 330° C.
The tempering of the apparatus parts in contact with the melt is carried out by means of one or several heat carrier liquid circuits, and for example, by electrically heating the upper and lower covers 5 and 2 of the vessel 3.
The heat exchanger pipes 4a with the filter cartridges 4c installed, which are essential to the process, are in direct contact with the heat carrier fluid, which enters at 3a and exits at 3b. For improved heat transfer performance the segmental disk baffles 3c cause the heat carrier fluid to flow mainly perpendicular to the pipes 4a. In comparison with the diameter of the pressure vessel used in the prior art filtration, the diameter of the heat exchanger pipes is very small. As a result, the use of thin-walled pipes with excellent heat transfer is possible. In order to exclude areas of increased melt viscosity with the consequence of low flow speed resulting in local polymer deposits on the wall 4a, the flow speed of the heat carrier fluid must be set high enough that the inlet and outlet temperatures of the heat carrier fluid are nearly equal (±1° C.).
Depending on the process stages which are placed before or after the filtration stage, the exit temperature of the polymer melt may equal the inlet temperature of the melt, or may diverge either upwardly or downwardly from the inlet temperature. For identical inlet and outlet temperatures of the polymer, i.e., within measuring precision, ±1° C., the difference between the temperature of the polymer melt and the entrance temperature of the heat carrier fluid should be as small as possible within the range of 1° to 5° C.
If the exit temperature of the polymer melt differs from the inlet temperature normally by 2° to 10° C. then a higher temperature difference between the entrance temperatures of the polymer melt and the heat carrier fluid, in the range of 5° to 20° C. is necessary. In this case, the filtration device which is used in accordance with the invention is particularly advantageous since, in the process of the invention--in a manner different from the known processes, which require both a complete heat exchanger as well as also a complete filtration apparatus--a single device, which unites the function of both apparatuses in itself, is sufficient.
The process in accordance with the invention is suited for the filtration of any polymer melts, on the presupposition that the flow speed of the polymer melts between the inlet into and the outlet from the filtration device is high enough to rule out thermal damage of the polymer. Polyamides, polycarbonates, polyolefines and linear polyesters, particularly ethyleneterephthalate-homo- and -copolymers, may be treated successfully. The filtration of the polymer melts is preferably carried out after the exit from the last synthesis reactor or separator, and before the entrance into the final processing unit. The use in an earlier process stage is possible, but provides no economic advantage. The invention is preferably used in polymer synthesis processes with a directly-connected fiber spinning unit.
The process in accordance with the invention makes possible the filtration of polymer melts while ensuring a uniform residence time, as well as a very uniform temperature of all the polymer melt during the entire filtration process, both of which are indispensable for meeting the present-day quality requirements. This is attained by guiding the polymer melts into pipes, which concentrically encircle the filter cartridges at a defined annular space, by means of targeted secondary polymer streams for the rinsing of dead zones and through improved heat transfer through the integration of the filtration device into a pipe assembly heat exchanger.
By means of the homogenous through-flow and the very uniform tempering, both the thermal damage of the polymer, as well as the polymer deposits in the filter casing and within the filter cartridges, are reduced. By that means, the running time between two cleaning cycles is extended by at least 50%. In addition, the cleaning of the filter cartridges is distinctly simplified since, after the removal of the upper cover, every filter cartridge can be individually removed and replaced with a clean one, without the entire filtration system having to be cooled off. In the prior art process which is described above, the entire system must be first cooled off, then the very heavy filter plate with all the filter cartridges be lifted off and, after the changing of the cartridges, installed again, and the entire system heated up again.
The invention further provides a targeted adjustment of the exit temperature of the polymer melts to a higher or lower value than the inlet temperature, without the use of an additional heat exchanger. | A process for filtering polymer melt which minimizes the generation of dead zones in the filter and provides uniform residence time and accurate temperature control. The process is carried out in an apparatus comprising a plurality of heat exchanger pipes, each enclosing a filter cartridge surrounded by an annular space which terminates at its upper end in a plurality of narrow channels. The molten polymer is charged into the annular space and divided into primary and secondary streams. The primary stream flows through the filter cartridge and the secondary stream, which constitutes 0.03 to 3.0 weight percent of the weight of the combined streams, flows through the narrow channels, whereupon the streams are combined and discharged from the apparatus. The discharge temperature of the polymer is maintained within ±1° C. of the charging temperature and the heat exchanger fluid enters the apparatus at a temperature within 1° and 5°C. of the temperature of the melt. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to electrical switch devices for selectively controlling the continuity of electrical circuits and more particularly to electromechanical relays for performing this function.
Over the years, electromechanical relays have found wide and varied application in the telephone and related arts and have assumed many structural forms. Basically, a relay of the character contemplated herein comprises an electromagnet, an armature, and a contact spring assembly, the armature being actuated to control the closing and/or opening of the contacts when the electromagnet is energized. Although in recent years solid state devices have replaced such relays in many communication systems, relays still offer many advantages in terms of cost, reliability, and versatility, for example, in circuit applications where the highest operative speed is not a requirement. Where the relays are operated in conjunction with electronic devices, the reduction in physical size of the latter components has also dictated a miniaturization of the relays and a number of miniature relay structure forms are also known in the art. When relays are to be used with printed circuit boards, for example, high packing density requires that the relay present a minimum profile and mounting area.
An important factor in the manufacture of any relay of whatever form an size, of course, is cost, especially when large numbers of the relays are to be produced. Any significant savings which may be realized in the assembly, inspection, and testing of a relay during its fabrication could thus be substantial in the aggregate. The inspection and testing phase of relay fabrication in particular has in the past added to the cost of manufacture in that a discovered defect frequently necessitated discarding an entire unit. Thus, if after final assembly, either the contact spring subassembly or the electromagnetic actuator subassembly proved defective, the entire relay might be rejected. Accordingly, in this particular area alone, costs could be halved, if the subassemblies were independently testable.
Accordingly, it is an object of this invention to make possible the independent testing of electromechanical relay subassemblies.
It is another object of this invention to minimize the profile and mounting area of an electromechanical relay without reducing its operating efficiency.
It is also an object of this invention to provide a new and improved electromechanical relay construction which is more readily assembled and disassembled than prior relay structures.
SUMMARY OF THE INVENTION
The foregoing and other objects of the invention are realized in one illustrative embodiment thereof comprising, in one aspect, a relay construction in which the electromagnetic actuator and the contact spring pile are fabricated as distinct and independent functional entities prior to final assembly. More specifically, the armature of the actuator assembly has its return spring constructed as an integral part thereof. As a result, the actuator assembly may be independently tested for the actual force available for contact spring operation compared to the test currents applied to the electromagnet. Similarly, the contact spring subassembly may be mechanically and electrically independently tested and screened before final assembly. Advantageously, if either subassembly should prove defective or unacceptable, it may be rejected and replaced without involving the other. A low profile is achieved by the novel magnetic actuator arrangement in which the armature is pivotally mounted across the upper surface of the open legs of a substantially U-shaped core, the coil being mounted about the base of the core. The contact spring subassembly is mounted across the under surfaces of the same core legs.
According to another aspect of the invention, an armature hinge arrangement is featured which minimizes the loading effect of the flex spring hinge. Specifically, an armature hingestop is provided which prevents displacement of the hinge spring during armature release by the normal force of the contact spring pile.
Another feature of a relay construction according to this invention is a novel coil terminal which is rotatably mounted in each of the coil bobbin end heads. In a first position a terminal end is rotated out from the bobbin to provide soldering access and then is rotated 90° to a final, more recessed position to provide wire slack and wire protection.
BRIEF DESCRIPTION OF THE DRAWING
The organization and operation of an electromechanical relay construction according to the principles of this invention together with the foregoing and other objects and features thereof will be better understood from a consideration of the detailed description of one illustrative embodiment which follows when taken in conjunction with the accompanying drawing in which:
FIG. 1 depicts in three-quarter perspective and exploded view one specific illustrative two-section relay construction according to this invention;
FIG. 2 is a plan top view of the relay construction of FIG. 1 as assembled;
Fig. 3 is an enlarged section view of the relay construction of the view of FIG. 2 taken along the line 3--3; and
FIG. 4 is an end view of the coil assembly of the relay construction of the view of FIG. 2 as seen from the line 4--4.
DETAILED DESCRIPTION
Turning now to the drawing and particularly FIG. 1 thereof, an illustrative relay arrangement according to this invention is seen in exploded view as comprising an electromagnetic actuator subassembly 10 and a contact spring subassembly 50. The actuator subassembly comprises a coil 11 wound on a bobbin 12, only the end heads 13 and 14 of which are visible in that view. The bobbin 12, also shown in FIG. 2 and 4, is advantageously split along its longitudinal axis to present two halves to facilitate its fitting about the base of a U-shaped core 15 having forwardly extending legs 16 and 17 as viewed in the drawing. Other details of the coil 11 and bobbin 12 will be described hereinafter. A flat armature 18 is positioned transversely across the core legs 16 and 17 which have rectangular cross-sections. The armature 18 is pivotally mounted at one end on leg 16 of core 15 by means of a hinge assembly comprising an end clip 19 having a lug 20 at each end extending over the top of core leg 16, the clip 19 also having a portiond downwardly extending along the outer wall of leg 16 comprising a pair of spring clasps 21, only one of which is visible in FIG. 1. The general configuration of the clip 19 is more clearly seen from a similar clip 22 mounted on the side wall of leg 17 of core 15 which clip 22 also presents a pair of spring clasps 23. The function of the clips 19 and 23 will become apparent from the description of the contact spring subassembly 50 hereinafter. The armature hinge 24 itself is mounted directly on core leg 16 between clip lugs 20 and comprises a thin flat flexible spring having a pair of clasps 25 for enclosing and retaining the pivotal end of armature 18. Hinge 24 is also provided with an additional pair of clasps 26 for retaining a hinge plate and hinge stop 27, the relationship of which with the armature 18 is more clearly seen in the section view of FIG. 3. The hinge stop 27 is adapted to prevent any movement of the armature 18 at its pivotal end away from the core leg 16 due to flexion of the spring hinge 24.
Turning to the other end of armature 18, another clip 22, as already mentioned, is seen in FIG. 1 as being mounted on the outer wall of core leg 17. Clip 22 is additionally provided with an armature backstop 28 to limit the pivotal travel of armature 18, the backstop 28 riding in a recess provided therefore in the armature end. The core 15 and armature 18 are fabricated from a magnetic material suitable for completing a magnetic flux path as is known in the relay art, the stops 27 and 28 being formed of a nonmagnetic material. At the free end of armature 18 and downwardly extending therefrom as viewed in the drawing, is mounted a contact spring actuator card 29 by means of a retaining clip 30 more clearly shown in the section view of FIG. 3. The card 29 is formed of an electrically insulating material and also forms a bearing surface for an armature return spring 31, which spring 31 is advantageously fabricated as an integral part of the electromagnetic actuator subassembly.
The latter spring is substantially U-shaped, its legs being firmly maintained between the upper surface of core leg 16 and the lugs 20 of end clip 19, the legs also having clasps for enclosing the latter lugs. As shown particularly in the top plan view of FIG. 2, the legs of the return spring 31 lie outside of the profile of armature 18 and parallel with the outer edges thereof. The base of spring 31 passes transversely under armature 18 to ride, under spring tension, on surfaces provided on card 29 to maintain armature 18 in its normal position against backstop 28. The metallic elements of the actuator subassembly 10 thus far described may be welded in place or otherwise suitably affixed as indicated as most convenient during manufacture.
The second section of an illustrative relay arrangement according to this invention is shown in FIG. 1 and 3 as comprising a contact spring subassembly 50 which in turn comprises a base mounting plate 51 and its contact spring piles. The mounting plate 51 is formed of a non-magnetic material and is provided at each end with a pair of lugs 52 and 53, which at final assembly, are adapted to be clasped by the spring clasps 21 and 23, respectively, of the clips 19 and 22 of actuator subassembly 10. Mounted on plate 51 is an exemplary plurality of contact spring pairs, one pair, springs 54 and 55, of which are shown in the section view of FIG. 3. The contact spring pairs terminate at one end in downwardly extending terminals 56-57. The individual springs of the spring pairs are separated by insulating spacers 61. As shown in FIG. 3, each of the springs of the spring pairs of the illustrative embodiment being described is normally closed with a back contact connected to a terminal 58 and 59 downwardly extending from the other end of the spring subassembly. Thus, the exemplary spring pair 54 and 55 is shown in FIG. 3 as being normally closed by means of break contacts 62 with terminals 58 and 59, respectively. A normally open make contact 63 on the back of each the upper springs is adapted to close a connection between the individual springs 54 and 55 of the spring pairs when the relay is energized. The individual terminals 58 and 59 are also suitably separated by insulating spacers 61. The spring pairs and terminals together with the insulating spacers are firmly maintained on mounting plate 51 by means of clamps 64 and 65 encircling the individual piles and engaging by means of suitably provided slots, lugs extending from each side of the plate 51 as more clearly seen in FIG. 1. A rectangular aperture 66 in mounting plate 51 in registration with the downwardly extending flange of actuator card 29 of subassembly 10 provides access for the latter flange to the contact spring piles as seen in FIG. 1 and in the sectional assembled view of FIG. 3.
An advantageous feature of a relay construction according to this invention is a novel coil terminal arrangement. As shown in FIG. 2, a pair of terminals 32 and 33 extend outwardly from the bobbin end heads 13 and 14 along an axis parallel to the longitudinal axis of the bobbin 12. Conventionally, the ends of the coil winding are soldered to these terminals and the terminals provide means for making electrical connections to external control circuitry. According to this invention, the terminals 32 and 33 comprise substantially L-shaped members one leg of each of which is staked in its respective bobbin head to be pivotal through at least 90° in a slot provided therefor in the bobbin head. Thus, as shown in FIG. 2, the terminals 32 and 33 are shown in their final positions and in positions indicated in dashed outline rotated 90° counterclockwise and clockwise, respectively. The terminal 33 is similarly shown in the end view of FIG. 4 in its position extending outwardly as viewed in the drawing and in a position extending perpendicularly from the bobbin axis. The latter positions for both terminals 32 and 33 are preassembly positions in which the terminals are more readily accessible for soldering the winding ends. After soldering has been completed the terminals are rotated to their final positions which conveniently slackens the winding wire ends to prevent subsequent strain and possible breakage after installation of the relay. Moreover, the final rotations of the terminals 32 and 33 moves the solder joints behind protective overhangs 34 and 35 formed on the end heads 13 and 14, respectively, and extending outwardly therefrom. Additional protection of the terminal connections is thus afforded to enhance relay reliability.
The operation of the relay of this invention after final assembly and installation is conventionally accomplished by the energization of coil 11 under the control of the circuit in which the terminals 32 and 33 may be connected in a system application. The resultant pivotal movement of armature 18 causes actuator card 29 to operate the contact spring pairs. As seen in FIG. 3 in connection with exemplary contact springs 54 and 55, contacts 62 are caused to open as a result and contact 63 closes a connection with spring 55. It will be appreciated that the operation of a single spring pair in the manner just described permits a number of options in circuit control merely by varying the circuit interconnections with the spring and contact terminals. It will also be understood that the contact spring organization shown in the drawing is illustrative only and that other spring arrangements known in the art may be mounted on plate 51 and operated by the single actuation of armature 18. In practice the relay arrangement according to this invention would be provided with suitable protective covers for both the actuator subassembly 10 and contact spring subassembly 50. These are not shown in the drawing and a detailed description of such enclosures is not considered necessary for a complete understanding of a relay construction according to this invention.
What has been described is considered to be only one specific illustrative relay embodiment according to this invention and it is to be further understood that various and numerous other arrangements may be devised by one skilled in the art without departing from the spirit and scope thereof as defined in the accompanying claims. | An electromechanical relay construction in which the electromagnetic actuator assembly and the contact spring subassembly are structurally and functionally distinct entities prior to final assembly. Specifically, the electromagnetic actuator assembly incorporates the armature return spring making possible independent testing of the actuator assembly for the actual force available for contact operation as compared to the current applied. Other features include an armature hinge stop for preventing excessive hinge spring displacement upon operation and rotatable coil terminals for facilitating soldering and providing wire protection and slack. | 7 |
TECHNICAL FIELD
The invention relates to the field of technology and hardware for earthmoving operations predominantly in replacement of the insulation coating of ducts, performed at the design elevations of ducts in the trench, predominantly without interrupting the operation of the insulation coating replacement, and more particularly to the methods and devices for padding the ground below a duct using excavated soil, equipment for soil compacting below a duct and soil compacting mechanisms. Furthermore, the invention can find an application in earth-moving operations in construction of new underground ducts.
BACKGROUND OF THE INVENTION
The advantages of such a technology of replacement of the insulation coating on operating ducts in the trench became obvious long ago to the experts who began making certain efforts for its introduction into practice. Known is the technology of replacement of the insulation coating, in which the duct is held above the trench bottom by stationary supports [S. A. Teylor. “Mechanising the operations on replacement of the insulation coating of operating ducts in the trench” // Neft′, gaz i neftekhimia za rubezohm, 1992, #10, p. 75-83]. In this case padding the ground below a duct is performed by regular earth-moving and construction machinery, due to the use of the above supports. However, the regular construction machinery does not provide a satisfactory solution for the problem of padding the ground below a duct using excavated soil, even when the above supports are applied. It is preferable to replace the insulation coating of the duct during continuous displacement of the entire system of the appropriate equipment without making use of the above supports. This requires more from the technology and equipment for padding the ground below a duct using excavated soil (feeding excavated soil from the dump, its deposition into the trench and compacting below the duct), which requirements cannot be met by the used in practice technology for performing the above-mentioned operations or the construction machinery, or by the other technologies and appropriate hardware which are not used in practice but are known from the state-of-the-art. In this case, the technology of padding the ground below a duct using excavated soil should envisage, and the appropriate device should be capable of, performing its function during its continuous uninterrupted displacement at a velocity which is equal to the velocity of displacement of the entire system (preferably 150 to 100 m/h), and the device should apply a minimal force on the insulation coating, which excludes damage to the coating even at its low strength, as when padding the ground below a duct after a small interval of time (3 to 7 min.) after application of the insulation coating, this time not being enough for some kinds of the coating to acquire its full strength. Furthermore, the device for padding the ground below a duct using excavated soil should have minimal overall dimensions in the direction along the duct for reduction of the length of the unsupported section of the duct to such an extent, as to eliminate or minimize the use of mobile means of supporting a duct. The device should provide a rather high degree of padding the ground below a duct (characterised by a bed coefficient K y equal to 0.5 to 1 MN/m 3 ) in order to avoid the significant subsequent slumping of the duct and appropriate deformation loads in it. Furthermore, the device for padding the ground below a duct using excavated soil should operate in a reliable manner when displaced over the surface of soil with significant unevenness and a lateral gradient, as well as over soil with low load-carrying capacity, for instance marshland or a layer of loose excavated soil. It is exactly the absence at the present time of such a technology and means for padding the ground below a duct using excavated soil which largely prevents a broad use in practice of the technology of replacement of the insulation coating on the operating ducts in the trench without the use of supports for the duct resting against the trench bottom. Thus, the inventors were faced with a complicated and important problem unsolved in a manner required for practical application, despite the numerous attempts at solving it for many years.
Known is a method of padding the ground below a duct which includes picking-up soil, its deposition into the trench from both sides of the duct and soil compacting in the space below the duct by rammer-type soil compacting organs applying a force on the soil previously deposited in the trench, during continuous displacement over the soil surface along the duct of a vehicle carrying soil feeding and soil compacting organs. Unlike the claimed method, in the known method the travelling unit with a wider base of the vehicle, moves along both edges of the trench, over the soil surface formed during uncovering of the duct, and the soil is picked up from the trench edges (Vasilenko S. K., Bykov A. V., Musiiko V. D. “Technology and system of technical means for overhauling the line oil pipelines without lifting the pipe” // Truboprovodni transport nefti, 1994, #2, p. 25-27]. The vehicle displacement along both edges of the trench complicates the process of placement on and removal from the uncovered duct, possibly causing emergency situations if the vehicle falls off the trench edge and non-uniform slumping of the travelling unit of the vehicle. Furthermore, soil picking-up from the trench edges unreasonably increases the scope of earth-moving operations.
The closest known method to the claimed method is the method of padding the ground below a duct using excavated soil, which include soil picking-up from the dump, soil transportation in the direction from the dump towards the trench with the duct, soil deposition into the trench from both sides of the duct and filling at least part of the trench space with soil, during continuous displacement over the surface of the soil along the duct of a vehicle carrying the soil feeding and transport organs, and compacting the soil at least in the space below a duct by soil compacting organs applying a force on the soil during continuous displacement over the soil surface along the duct, of a vehicle carrying soil compacting organs. Unlike the claimed method, in the known method the vehicle carrying the soil feeding, transport and soil compacting organs, is displaced over the soil surface from the trench side opposite to the dump, whereas the force is applied to the soil by soil compacting organs made in the form of throwers, prior to its deposition into the trench, which accelerate the soil up to the velocity sufficient for dynamic self-compacting of the soil during its deposition into the trench [USSR Author's Certificate 855137, IPC E02F 5/12, 1981]. Displacement of the vehicle over unprepared soil surface results in the vehicle, and the soil compacting organs together with it, rocking when passing over uneven ground, with soil particles (in particular, large-sized rocky inclusions) hitting the surface of the duct insulation coating at a high speed, and breaking it. Furthermore, even with a stable position of the vehicle, it is impossible to direct the high-speed flow of soil below a duct with such a precision as to, on the one hand, eliminate formation of a cavity under the duct, and on the other hand, prevent collision of the high speed soil particles with the insulation coating surface. This method does not permit achievement of the required degree of compacting of soil below a duct, which would provide small enough slumping of the duct, and, therefore, its small deformation loading, this being especially important in performance of this work without interruption of the duct operation. This method is difficult to implement when excavated fertile soil is located on the trench side opposite to that of the mineral soil dump location. For its implementation, this method requires an appropriate device with a long extension of soil feeding organ, this being difficult to implement in technical terms. Moreover, this process of padding ground below a duct involves higher power consumption.
The closest to the claimed device, is a device known from prior art for padding ground below a duct using excavated soil, which comprises a vehicle with the travelling unit for displacement over the soil surface, carrying the equipment for filling the trench with excavated soil, which includes the soil feeding and transport organs and a device for lifting-lowering of the soil feeding organ relative to the vehicle, and equipment for soil compacting below a duct, including a soil compacting mechanism with drive soil compacting organs and a device for hanging the soil compacting mechanism from the vehicle with the capability of forced displacement and securing relative to the vehicle in a plane which is normal to the direction of its displacement. Unlike the claimed device, in the known device the soil feeding organ is located to the side of the vehicle with a large extension relative to it, for allowing its displacement on the trench side opposite to the dump. The soil feeding and transport organs are designed as one working organ of the screw conveyor hung from the vehicle with a device for hanging the soil compacting mechanism, and the soil compacting organs are made in the form of driven soil throwers whose inlets are connected to the soil outlets of the equipment for filling the trench. Here, the soil compacting mechanism includes the drive mechanism of rocking of the soil compacting organs [USSR Author's Certificate # 855137, IPC E02F 5/12, 1981]. The known device has all the disadvantages indicated above for the appropriate method. Furthermore, the known device is not stable enough in the transverse plane, has higher power consumption for picking-up the soil, its feeding and deposition into the trench, the screw-conveyor type working organ and the throwers are poorly adapted to operation in boggy sticky soils as a result of the soil sticking to them.
The closest known equipment to the claimed equipment is the equipment for soil compacting below a duct, incorporating a soil compacting mechanism and a device for hanging the soil compacting mechanism to a vehicle, including an integrated mechanism for forced displacement and rigid fastening of the soil compacting mechanism relative to the vehicle in the plane normal to the vehicle displacement direction [USSR Author's Certificate 855137, IPC E02F 5/12, 1981]. Because the known device for hanging the rammer-type soil compacting mechanism lacks a disconnection mechanism for a cyclic displacement of soil compacting organs relative to the vehicle in the direction of its movement, it will be impossible to perform continuous displacement of the vehicle during the soil compacting. This is an especially significant disadvantage for a device which is designed for use as part of a complex of earth-moving machinery in replacement of the insulation coating of a duct, performed on design elevations of the duct in the trench, predominantly without the use of supports for holding it, when a continuous and coordinated displacement of all the machinery of the complex along the entire duct is required.
The closest known mechanism to the claimed mechanism is a soil compacting mechanism known from prior art, incorporating a base which carries the drive soil compacting organs each of which includes a connecting rod with a soil compacting element at its lower end, lower lever which is connected to the connecting rod by its first hinge, and to the base by the second one, and upper lever which is connected to the upper end of the connecting rod by third hinge. Unlike the claimed mechanism, in the known mechanism, the upper lever is connected to the lever vibration mechanism, whereas the working surfaces of soil compacting elements are located in the radial direction relative to third hinges [USSR Author's Certificate #1036828, IPC E01C 19/34, E02D 3/46, 1983]. In the known mechanism, the soil compacting elements travel practically in the horizontal transverse direction with connecting rods rotation about the axes of third hinges. In this case, it is impossible to withdraw soil compacting elements from the soil for their displacement along the duct with a stable position of soil compacting mechanism relative to the duct, it is impossible to form below a duct a zone of soil compacting with slopes or provide uniform compacting of soil along the entire height of the space below a duct, especially with rather great above-mentioned height. for instance, of about 0.8 m. Operation of this mechanism is difficult or practically impossible in relatively narrow trenches. Another disadvantage of the known mechanism is its great height. complicating movement into the trench, withdrawing from the trench, and displacement of the vehicle with the soil compacting mechanism hung to it.
SUMMARY OF THE INVENTION
The main goal of the invention is to provide a method for padding the ground below a duct using excavated soil to minimize the stress applied by the soil to the surface of the insulation coating of a duct during its deposition while compacting the soil below a duct with a greater degree of soil compaction, and to eliminate damage to the insulation coating or duct by the soil compacting organs by providing a steady vehicle position through preparation of soil surface prior to vehicle displacement, and to reduce the power consumption of the deposition and soil compaction processes.
The above goal is achieved by the method for padding ground below a duct using excavated soil, including soil picking-up from the dump, soil transportation in the direction from the dump towards the trench with the duct, soil deposition into the trench from both sides of a duct to fill at least the space below a duct, and soil compacting, at least the space below a duct by applying stress to the soil by soil compacting organs during continuous displacement over the soil surface along the duct of one or two vehicles carrying the soil feeding, transport and soil compacting organs. The vehicle carrying at least the soil compacting organ can be displaced over the ground surface along a ground path formed by the soil feeding organ during soil feeding from the dump while stress is applied by soil compacting organs to the soil which has already been deposited into the trench.
Unlike the process of dynamic self-compacting of soil in its feeding under a duct at a high speed, the process of preliminary deposition of soil into the trench at a low velocity and its subsequent compacting, consumes less power, allows reduction of the stress applied by the soil to the insulation coating surface, and increases the degree of soil compacting. The probability of the duct being damaged by soil compacting organs in the claimed method is reduced by providing a stable vehicle position in its displacement over the soil surface which has been prepared by a soil feeding organ.
In particular embodiments of the invention, one vehicle is used, which is made in the form of a base frame carrying the soil feeding, transport and soil compacting organs.
Furthermore, part of soil from the dump is used to form the above ground path. In addition, in formation of the ground path, its grading in the transverse direction is performed by skewing the soil feeding organ in the plane normal to the direction of its displacement. In addition, in order to counteract an angle of skewing of the vehicle that results from non-uniform subsidence of soil under the vehicle travelling unit, the transverse gradient of the ground path is set equal in value and opposite in its direction to the angle of skewing of the vehicle relative to the surface of the ground path as a result of the non-uniform subsidence of soil under its travelling unit. Furthermore, part of the soil from the transport organ is unloaded on the ground strip located between the vehicle travelling unit and the trench. In addition, the stress is applied to the soil for its compacting in a cyclic manner, the working elements of soil compacting organs being displaced in each compacting cycle in a plane normal to the direction of the vehicle displacement, in the downward direction and towards each other, whereas between the compacting cycles the working elements are moved in the displacement direction of the vehicle. In addition, the above working elements are rotated in the above-mentioned plane in the direction so the angle they define becomes smaller. In addition, during displacement of the working elements in the displacement direction of the vehicle, they are at least partially withdrawn from the soil. Furthermore, with the design force on the working elements, their actual position is determined, which is compared with the appropriate design position, and proceeding from the comparison results, the level of filling the trench with the soil is kept the same, or increased or lowered. In addition, the trench is filled with the soil up to the level which is higher than the level required for padding ground below a duct, while the displacement of the working elements in the displacement direction of the vehicle is performed with the working elements lowered into the soil. In addition with the design force on the working elements, their actual position is determined, which is compared with their appropriate design position, and proceeding from the comparison results, the level of lifting the working elements is kept the same, or increased or lowered. In addition, compacting the soil is performed with a constant maximal force on the working elements and specific pitch of compacting. Furthermore, the specific pitch of compacting is increased when increasing the maximal force on the working elements, and vice versa. In addition, the maximal force on the working elements is increased if the vehicle carrying the soil compacting equipment is skewed in the direction towards the trench, and vice versa.
Another goal of the invention is to provide a device for padding ground below a duct using excavated soil, by making rammer-type soil compacting organs which are hung to the vehicle using a disconnection mechanism and placing the soil feeding organ at an end face of the vehicle for formation of the soil surface over which the vehicle moves, to provide a minimal stress application by the soil on the insulation coating surface during padding ground with a greater degree of soil compacting, to lower the power consumption of the ground padding process and to eliminate damaging of the insulation coating by soil compacting organs.
The above goal is achieved by the device for padding ground below a duct using excavated soil, incorporating at least one vehicle with the travelling unit for displacement over the soil surface, which carries the equipment for filling the trench with the duct by excavated soil, including soil feeding and transport organs and a device for lifting-lowering the soil feeding organ relative to the vehicle, and equipment for compacting soil below a duct, including a soil compacting mechanism with drive soil compacting organs and a device for hanging soil compacting mechanism from the vehicle with the capability of forced displacement and rigid fastening relative to it in a plane which is normal to the direction of its displacement. According to the invention the soil feeding organ is located at the end face of the travelling unit and is wider than the travelling unit, and the device for hanging the soil compacting mechanism is fitted with a disconnection mechanism for cyclic displacement of soil compacting organs relative to the vehicle in its displacement direction, the soil compacting organs being of the rammer-type and being located behind the zone of soil unloading from the transport organ in the displacement direction of the vehicle.
Unlike the throwers, the rammer-type soil compacting organs are less power-consuming and provide a greater degree of soil compaction with a smaller damaging action of the soil on the insulation coating. The disconnection mechanism ensures normal functioning of soil compacting mechanism during continuous displacement of the vehicle whose stabilizing is provided by the soil feeding organ, thus lowering the probability of the damaging action of soil compacting organs on a duct.
In particular embodiments of the invention, the equipment for filling the trench with the duct by excavated soil is fitted with a device for forced rotation of soil feeding organ relative to the vehicle in a plane which is normal to the displacement direction of the vehicle. In addition, the equipment for filling the trench with the duct with excavated soil is made with at least two outlets for the soil, whose spacing in the horizontal direction normal to the direction of displacement of the vehicle is greater than the duct diameter. In addition, the device for hanging the soil compacting mechanism from the vehicle includes connected to each other mechanisms for forced lifting-lowering, transverse displacement and rotation of soil compacting mechanism. In addition, soil feeding, transport and soil compacting organs are hung from one vehicle made in the form of a base frame.
A goal of the invention is to provide equipment for padding ground below a duct with the capability of normal functioning of rammer-type soil compacting mechanism during continuous displacement of the vehicle by fitting the equipment with a disconnection mechanism.
This goal is achieved by the equipment for padding ground below a duct, including soil compacting mechanism and a device for hanging soil compacting mechanism to the vehicle, incorporating an integrated mechanism for forced displacement and rigid fastening of soil compacting mechanism relative to the vehicle in a plane normal to the direction of its displacement. According to the invention, the device is fitted with a disconnection mechanism for cyclic displacement of soil compacting organs relative to the vehicle in its displacement direction, which incorporates a kinematic joint which is included into a sequence of kinematic elements of the above-mentioned integrated mechanism, and has a degree of mobility in a plane which is parallel to the direction of the vehicle displacement.
In particular embodiments of the invention, the above-mentioned integrated mechanism incorporates the connected to each other mechanisms for forced lifting-lowering, transverse displacement and rotation of the soil compacting mechanism. In addition, the above-mentioned kinematic joint of the disconnection mechanism is made in the form of a hinge with the axis of rotation located in a plane normal to the direction of the vehicle displacement. In addition, the above-mentioned axis of rotation is located horizontally. In addition, the disconnection mechanism is fitted with at least one elastic element connected with the rigid elements which are connected to each other by the above hinge and form a kinematic pair. In addition, the disconnection mechanism is fitted with a longitudinal feed power drive connected to rigid elements which are connected to one another by the above hinge and form a kinematic pair. In addition, the integrated mechanism is made in the form of a lifting boom which with its root is connected by means of the first hinge and lifting-lowering power drive to the support mounted on the vehicle frame, and an arm which with its first end is connected by a kinematic connection, which includes the second hinge and transverse displacement power drive, to the head part of the lifting boom, and with its second end is connected by means of third hinge and power drive of revolution to the soil compacting mechanism, the above kinematic pair of the disconnection mechanism including the boom head part and a shackle which is connected to the first end of the arm by the above-mentioned second hinge.
Another goal of the invention is to provide a soil compacting mechanism by changing the connections and relative position of its elements, to provide displacement of soil compacting elements in the vertical and horizontal directions, which is sufficient for a high degree of compacting the soil below a duct and formation of a zone of soil compacting with slopes, in order to prevent breaking up of the soil with the duct resting on it, to provide soil compacting along the entire height of the space below the duct, in narrow trenches and at a great height, to provide lifting of soil compacting elements above the soil for their longitudinal feed with a stable position of soil compacting mechanism relative to the duct; to reduce the height of soil compacting mechanism for facilitating its introduction into/withdrawal from the trench.
This goal is achieved by the soil compacting mechanism incorporating the base which carries the drive soil compacting organs, each of which includes the connecting rod with the working element at its lower end, a lower lever which is joined to the connecting rod by its first hinge and to the base by the second hinge, and an upper lever which is connected by a third hinge to the upper end of the connecting rod. The upper lever is connected by the fourth hinge to the base, the fourth hinge being shifted relative to the second hinge in the direction of the connecting rod, and/or the distance between the first and third hinges is greater than the distance between the second and fourth hinges, and/or the distance between the third and fourth hinges is greater than the distance between the first and second hinges.
In particular embodiments of the invention, the working surfaces of the working elements in their upper position arc located horizontally or are facing each other and are located at an angle of not less than 90° to each other. In addition, the working surfaces of the working elements in their lower position define an angle which is in the range of 60 to 120°. Furthermore, the distance along the vertical between the working element of each soil compacting organ in its extreme upper and extreme lower positions is not less that half of the duct diameter, and the appropriate distance along the horizontal is not less than half of the above distance along the vertical. In addition, the base incorporates a beam and brackets which carry at least the upper and lower levers of soil compacting organs, and which are secured on the beam by detachable joints with the capability of placing them into at least two positions along the beam length. Furthermore, the power drive of each soil compacting organ is made in the form of a hydraulic cylinder hinged to the upper lever and the base. In addition, the upper levers are made as two arm and L-shaped levers, the mechanism being fitted with a synchronising tie rod hinged by its ends to second arms of upper levers.
BRIEF DESCRIPTION OF THE DRAWINGS
Other details and features of the invention will become obvious from the following description of its particular embodiments, with references to the accompanying drawings, which show:
FIG. 1 —preferable embodiment of the claimed device in the form of a machine for padding ground below a duct using excavated soil with left-handed position of suspended equipment, side view;
FIG. 2 —same, top view;
FIG. 3 —machine for padding ground below a duct using excavated soil with right-handed position of suspended equipment, front view of filling equipment;
FIG. 4 —same, front view of compacting equipment;
FIG. 5 —preferable embodiment of the equipment for filling the trench with excavated soil, side view;
FIG. 6 —same, top view;
FIG. 7 —component A in FIG. 6;
FIG. 8 —B—B cut in FIG. 7;
FIG. 9 —C—C cut in FIG. 7;
FIG. 10 —soil divider, top view;
FIG. 11 —view F in FIG. 10;
FIG. 12 —view D in FIG. 10;
FIG. 13 —E—E cut in FIG. 10;
FIG. 14 —preferable embodiment of the equipment for soil compacting below a duct, rear view;
FIG. 15 —component M in FIG. 4;
FIG. 16 —Z view in FIG. 15;
FIG. 17 —N—N cut in FIG. 16;
FIG. 18 —K view in FIG. 14;
FIG. 19 —an embodiment of the equipment for soil compacting below a duct, rear view;
FIG. 20 —mounting a contactless sensor of the duct position on a belt conveyor;
FIG. 21 —mounting a contactless sensor of the duct position and sensor of gravity vertical position on the base of soil compacting mechanism;
FIG. 22 —view S in FIGS. 20 and 21;
FIG. 23 —mounting the sensor of soil feeding organ rotation;
FIG. 24 —block-diagram of the device of machine monitoring and control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The claimed method of padding ground below duct 1 with excavated soil 2 can be implemented in its preferable embodiment using the appropriate claimed device which in its preferable embodiment is made in the form of machine 3 for padding ground below a duct using excavated soil (further on referred to as machine 3 ), as is described further and explained by the drawings. In this case, the term padding ground below a duct using excavated soil, is used in the sense of filling trench 4 with duct 1 by excavated soil 2 and its compacting, at least, in space 5 below duct 1 .
Machine 3 consists of a vehicle which in this case is made in the form of one common base frame 6 with caterpillar unit 7 for displacement over the soil surface, hung to whose frame 8 are equipment 9 for filling the trench with the duct with excavated soil (further on referred to as filling equipment 9 ) and equipment 10 for soil compacting below a duct (further on referred to as compacting equipment 10 ). It is obvious to an expert that the claimed device for padding ground below a duct using excavated soil, can be made as a system of two machines (not shown in the drawing), in which case it will have two vehicles—caterpillar base frames, one of them carrying filling equipment 9 and the other—compacting equipment 10 .
Filling equipment 9 is made in the form of an earth-moving and transportation device for picking-up soil and feeding it upwards and in the direction which is normal to longitudinal axis 11 of base frame 6 (further on referred to as transverse direction). Filling equipment 9 includes a device for lifting-lowering soil feeding organ relative to the vehicle (base frame 6 ) which incorporates frame 12 hung to frame 8 of base frame 6 , with the capability of forced lifting and forced or gravity lowering (further on referred to as lifting frame 12 ), soil feeding 13 and transport 14 organs, as well as soil divider 15 located in the zone of soil unloading from transport organ. Soil feeding 13 and transport 14 organs are mounted on lifting frame 12 . Soil feeding organ 13 is made with the capability of continuously feeding excavated soil 2 or newly unturned ground and is located at the end face of base frame 6 , its width L b1 , being greater than the width L b2 of caterpillar travelling unit 7 of base frame 6 so that the surface of the soil formed by the soil feeding organ 13 after its passage, makes a ground path 16 of sufficient width for displacement of travelling unit 7 over it. For grading the path 16 in the transverse direction, soil feeding organ 13 is connected to travelling unit 7 with the capability of its forced rotation in a plane normal to longitudinal axis 11 of base frame 6 (further on referred to as transverse plane). Filling equipment 9 can have different design embodiments, for instance, soil feeding 13 and transport 14 organs can be mounted with the ability of simultaneous rotation about an imaginary geometrical axis of rotation 17 (further on axis of rotation 17 ), or as shown in FIGS. 5, 6 , only the soil feeding organ is mounted with the ability of revolution about axis of rotation 17 . In this case, in order to reduce the lateral linear displacement of lower part of soil feeding organ 13 when forming ground path 16 , in its revolution about axis of rotation 17 , the vertical distance h 1 (FIG. 5) from the axis of rotation 17 to the surface of the ground path 16 should be minimal.
In the general case, soil feeding organ 13 can be made of different types, for instance, chain, rotor, screw-conveyor or combined, the most preferable embodiment, however, being the chain variant of soil feeding organ 13 , with widegrip soil feeding chain 18 . In this case soil feeding organ 13 incorporates frame 19 with inclined flat breast 20 and side panels 21 between which soil feeding chain 18 is located, mounted on drive 22 and tension 23 sprockets of drive 24 and tension 25 shafts. Soil feeding chain 18 is formed in the preferable embodiment, as shown in the drawings (FIGS. 2, 3 , 6 ), by four hauling chains 26 bending to one side, which are connected to each other by soil transporting beams 27 which are arranged in three rows, with beams in adjacent rows shifted along and overlapping across soil feeding chain 18 . In other embodiments. the number of hauling chains 26 and of rows of soil transporting beams 27 , respectively, can be larger or smaller. Replaceable cutters 29 are mounted on beams 27 in cutter holders 28 . Drive shaft 24 preferably consists of right 30 and left 31 co-axial half-shafts which are connected to each other by gear-type or other coupling 32 . On each of the half-shafts 30 , 31 two drive sprockets 22 are tightly fitted, outside which bearing supports 33 are located by means of which half-shafts 30 , 31 are mounted on first transverse beam 34 of frame 19 . Beam 34 is fixedly connected by its end faces to side panels 21 . Longitudinal beams 36 which carry rollers 37 supporting hauling chains 26 , are located between and connected by their end faces to first transverse beam 34 and second transverse beam 35 which is shifted towards tension shaft 25 relative to the first transverse beam. Tension sprockets 23 are mounted by means of bearings on a one-piece tension shaft 25 connected by its ends to side panels 21 by tension mechanisms 38 . In an alternative embodiment (not shown in the drawings) the tension shaft can be absent, and tension sprockets 23 can be mounted on a tension beam connected by its ends to side panels 21 by the tension mechanisms 38 .
One of half-shafts 30 , 31 of drive shaft 24 , for instance, the right one 30 (FIG. 9) is connected to drive 39 which can be made, for instance, in the form of hydraulic motor 40 , as shown in FIG. 1, or as in the preferable embodiment in FIG. 6, in the form of a mechanical transmission 41 connected to the power take-off shaft (PTO) (not shown in the drawings) of base frame 6 . Mechanical transmission 41 incorporates successively arranged in the direction of transfer of the torque and connected to each other first cardan shaft 42 , first reduction gear 43 with input 44 and output 45 shafts normal to each other, second reduction gear 47 with input 48 and output 49 shafts located at an angle to each other, second cardan shaft 50 which is made to be telescopic and enclosed into casing 51 , and third reduction gear 52 with input 53 and output 54 shafts located at an angle to each other. Output shaft 45 , input shaft 48 and the shaft 46 , which is connected to them by its ends, are co-axial with an imaginary geometrical axis 55 of rotation of hinges 56 by which frame 12 of filling equipment 9 is hung to frame 7 of base frame 6 . In this case, the axle 57 of hinge 56 (the right one in FIG. 6 ), is made tubular with a through hole for passing shaft 46 through it.
In the preferable embodiment of the invention (FIGS. 5, 6 ), frame 12 includes first part 58 located horizontally as shown in the drawings nominal working position of filling equipment 9 and located normal to the first part and fixedly connected to it second part 59 whose upper end accommodates located normal to it, first brackets 60 which by means of above hinges 56 , are connected to brackets 61 mounted on frame 7 . Made on the upper end of second part 59 are second brackets 62 located opposite to first brackets 60 relative to this part, to which second brackets the rods of hydraulic cylinders 64 for forced lifting-lowering of frame 12 , arc connected by means of axles 63 . The lifting hydraulic cylinders 64 are connected by means of axles 65 to brackets 66 made fast on frame 7 . Fastened rigidly on the front transverse beam 67 of first part 58 of frame 12 is tubular axle 68 whose imaginary geometrical axis is the axis of rotation 17 and is located in all positions in one plane with longitudinal axis 11 of base frame 6 , and in the earlier mentioned nominal working position is approximately parallel to longitudinal axis 11 . In this case, frame 19 of soil feeding organ 13 is fitted with bushing 69 which encloses front cantilever part of tubular axle 68 and is hinged to first part 58 of frame 12 by means of hydraulic cylinders 70 for forced rotation of soil feeding organ 13 about axis of rotation 17 . Hydraulic cylinders 70 of rotation are located under breast 20 , thus making the design of filling equipment 9 compact and preventing soil from falling on the hydraulic cylinders 70 .
In the preferable embodiment shown in the drawings, the transport organ 14 has a frame 71 of the belt conveyor 72 located in the transverse plane (normal to longitudinal axis 11 of the base frame), and is fastened on the first part 58 of frame 12 by a detachable joint. In this case, the detachable joint allows placing belt conveyor 72 in one of the two positions with the extension to the right (in FIGS. 3, 4 , 6 ) or to the left (in FIGS. 1, 2 ) of longitudinal axis 11 . Extension of conveyor 72 corresponds to the nominal distance from longitudinal axis 11 to longitudinal axis 73 of duct 1 . Belt conveyor 72 is of the standard known design and includes continuous belt 74 , two drums 75 , 76 enveloped by belt 74 , and drive of drum 75 made, for example, in the form of hydraulic motor 77 (FIG. 2 ).
Soil divider 15 preferably has the form of a gable roof and incorporates trays 78 inclined in the transverse plane with edges 79 , which are mounted on bushings 80 with the capability of rotation on axle 81 whose end parts 82 are mounted on spherical hinge bearings 83 in holes 84 of brackets 85 which are made on the first ends of levers 86 , 87 . Second ends of levers 86 , 87 are hinged to frame 71 of belt conveyor 72 by means of practically vertical axes 88 . Second end of lever 86 is fitted with bracket 89 which is hinged by axle 90 to the rod of hydraulic cylinder 91 for adjustment of the proportion of. soil flows coming out of divider 15 . The hydraulic cylinder of adjustment 91 is hinged to frame 71 of conveyor 72 . Mounted on axle 81 with a shift towards one of its ends, by means of bushings 92 with the capability of rocking, is cutoff shield 93 with brackets 94 which are connected by means of extension springs 95 and adjusting turn buckles 96 to edges 79 of trays 78 . The left (in FIG. 12) end face 97 of cut-off shield 93 comes practically right up to the left edges 79 , whereas the right end face 98 is located approximately half way between the left and right edges 79 . Trays 78 are located at an angle to each other and fixed in such a position by distance piece 99 whose ends are hinged to trays 78 , with a distance L b3 (FIG. 3) between lower end faces of trays 78 which are outlets for soil coming out of filling equipment 9 , the distance L b3 being greater than diameter D of the duct in the horizontal transverse direction. One of edges 79 of one of trays 78 has a welded-on plate 100 with slot 101 which accommodates the rest 102 made on one of brackets 85 . The width of slot 101 is larger than the respective dimension of the rest 102 , thus providing the capability of simultaneous rocking of trays 78 on axle 81 for their gravitational self-positioning at the same angle to the horizon. Levers 86 , 87 with hydraulic cylinder of adjustment 91 and their appropriate connections, represent a mechanism for displacement of soil divider 15 relative to conveyor 72 in the direction out of the plane of location of the latter. It is obvious that the above mechanism can also be of another design which provides appropriate displacement of divider 15 . Furthermore, it is obvious that the proportion of soil flows can be changed not only by displacement of entire divider 15 , but also by displacement along axle 81 of solely cut-off shield 93 with trays 78 being stationary relative to conveyor 72 .
Compacting equipment 10 includes soil compacting mechanism 103 with two drive rammer-type soil compacting organs 104 , 105 and device 106 for hanging to base frame 6 (vehicle) soil compacting mechanism 103 (further on referred to as suspension device).
Suspension device 106 includes integrated mechanism 107 for forced displacement and rigid fastening of soil compacting mechanism 103 relative to base frame 6 in the transverse plane, which preferably includes the connected to each other mechanisms for lifting-lowering 108 , transverse displacement 109 and rotation 110 of soil compacting mechanism 103 . In the preferable embodiment of integrated mechanism 107 , above-mentioned mechanisms 108 , 109 , 110 are made as follows.
Lifting-lowering mechanism 108 is made in the form of lifting boom 111 which with its root 112 by means of first hinge 113 is connected to bracket 114 with base plate 115 which has pin 116 in its center, located in the hole of horizontal base plate 117 of a support which is rigidly fastened on frame 8 of base frame 6 and is made in the form of gantry 118 . Base plates 115 , 117 are fastened to each other by bolts 119 with nuts 120 and washers 121 , with elongated slots 122 made in base plate 114 for above bolts 119 , thus providing the capability of rotation of bracket 114 about imaginary geometrical axis 123 of pin 116 when nuts 120 are loosened. Lock 124 is provided for a reliable securing of bracket 114 against rotation about axis 123 , the lock being made in the form of plate 125 with toothed quadrant 126 , tooth 127 and slots 128 for bolts 129 . Scale 130 and toothed quadrant 131 are made on base plate 115 for engagement with toothed quadrant 126 , while gantry 118 has welded to it base plate 132 with radial slot 133 for accommodating tooth 127 and threaded holes 134 for bolts 129 . Base plate 115 has additional toothed quadrant (not shown in the drawings) which is shifted relative to main toothed quadrant 131 by an angle of 180°, thus providing for positioning of lifting boom 111 with extension to the left or to the right of longitudinal axis 11 of base frame 6 . By means of lifting-lowering hydraulic cylinder 135 , boom 111 is hinged to left 136 or right 137 posts of gantry 118 , respectively.
The mechanism of transverse displacement 109 is made in the form of arm 138 whose first end 139 is connected to head part 140 of boom 111 , which is made L-shaped. In this case, the above-mentioned connection includes second hinge 141 , and hydraulic cylinder 142 of transverse displacement. Brackets 143 , 144 are made on first end 139 of arm 138 and head part 140 of boom 111 , the brackets being connected by hinges 145 , 146 to rod and case of hydraulic cylinder 142 , respectively. Second (lower) end 147 of arm 138 is connected by means of a third hinge 148 to base 149 of soil compacting mechanism 103 .
Rotation mechanism 110 is made in the form of above-mentioned hinge 148 and hydraulic cylinder 150 of rotation, whose rod and case are connected by means of hinges 151 , 152 to base 149 and arm 138 , respectively.
Suspension device 106 further incorporates a disconnection mechanism 153 for cyclic displacement of soil compacting organs 104 , 105 relative to base frame 6 in its displacement direction, thus providing the capability of soil compacting during continuous displacement of base frame 6 . Disconnection mechanism 153 is made in the form of hinge 154 which connects to each other head part 140 of boom 111 and shackle 155 which has lugs 156 connected by hinge 141 to arm 138 . That is, in this embodiment of suspension device 106 the connection of arm 138 with head part 140 of boom 111 includes, beside hinge 141 and hydraulic cylinder 142 , hinge 154 and shackle 155 . In other embodiments, however, hinge 154 can be connected at another point into the sequence of kinematic elements join in soil compacting organs 104 , 105 to base frame 6 . The geometrical axis of hinge 154 is located in the transverse plane, and is practically horizontal in the working position of compacting equipment 10 (FIGS. 4, 14 ). Geometrical axes of all hinges 113 , 141 , 148 of integrated mechanism 107 are located longitudinally, i.e. normal to the above transverse plane. Thus, in forced closure of hinges 113 , 141 , 148 by means of hydraulic cylinders 135 , 142 , 150 a rigid connection of soil compacting mechanism 103 with base frame 6 in the transverse plane is in place, i.e. any kind of its spontaneous displacement is eliminated. In this embodiment disconnection mechanism 153 is serviceable without any additional elements. It, however, can include elastic elements, made, for instance, in the form of spring adjustable shock absorbers 157 . Each shock absorber 157 is made in the form of rod 158 with threaded 159 and smooth 160 sections which carry stationary 161 and mobile supports 162 between which compression spring 163 is mounted. Mobile support 162 has spherical pivot 164 supported by plate 165 with a hole, which is welded on shackle 155 , whereas rod 158 has lug 166 connected by axle 167 to bracket 168 which is welded on head part 140 .
Soil compacting mechanism 103 includes base 149 on which are mounted soil compacting organs 104 , 105 and power drive 169 of soil compacting organs 104 , 105 . Each soil compacting organ 104 , 105 includes connecting rod 170 which has flat working element 171 attached to its lower end, lower lever 172 which is connected by first hinge 1773 to connecting rod 170 , and by second hinge 174 to base 149 , and upper lever 175 which by third hinge 176 is connected to upper end of connecting rod 170 , and to base 149 by fourth hinge 177 . In this case, in order to provide downward displacement towards each other of elements 171 , at least one of the following three conditions must be satisfied: the fourth hinge 177 should be shifted relative to second hinge 174 towards the connecting rod 170 , or; the distance between first 173 and third 176 hinges should be greater than the distance between second 174 and fourth 177 hinges, or; the distance between third 176 and fourth 177 hinges should be greater than the distance between first 173 and second 174 hinges. It is natural that simultaneous satisfying of two or preferably three of the above-mentioned conditions is possible, as in the preferable embodiment of the soil compacting mechanism shown in FIGS. 4, 14 , 19 . Base 149 is made composite and includes beam 178 and two brackets 179 , 180 which carry all the elements of soil compacting organs 104 , 105 . Brackets 179 , 180 are fastened by flange joints 181 through replaceable inserts 182 on end faces of beam 178 . Replaceable inserts 182 are designed for changing the spacing of brackets 179 , 180 , when the mechanism is set up for a particular duct diameter. Power drive 169 of each soil compacting organ 104 , 105 is made in the form of hydraulic cylinder 183 whose rod and case are connected by hinges 184 , 185 to upper lever 175 and bracket 179 or 180 , respectively.
In the above described and shown in FIG. 14 embodiment, soil compacting mechanism is fully serviceable; for synchronism the displacement of soil compacting organs 104 , 105 , however, it is rational to make upper levers 175 as two-arm and L-shaped levers, and fit the mechanism with synchronising tie rod 186 , connected by its ends to second arms 188 of upper levers 175 by hinges 187 , as shown in FIGS. 4, 19 . It is rational to make hinges 145 , 151 , 152 , 184 using standard spherical hinge bearings, and to make hinges 146 , 185 using double hinges of Hooke's joint type.
FIG. 19 shows another embodiment of compacting equipment 10 , in which suspension device 106 includes load-carrying structure 189 which is made in the form of a cantilever beam-made fast on base frame 6 , or in the form of a semi-gantry cross-bar resting at one end (for instance right end, FIG. 19) on frame 8 of base frame 6 which is located, for instance, on the right berm of the trench, and at the second end supported by its own caterpillar carriage which is located on the opposite (left) berm of trench 4 . In this case, mechanism 109 of transverse displacement is made in the form of a carriage 190 that is mobile along a load-carrying structure 189 and hydraulic cylinder 191 of transverse displacement. Lifting-lowering mechanism 108 is made in the form of a hinged to the carriage 190 two-arm L-shaped lever 193 whose first arm 194 is hinged to lifting-lowering hydraulic cylinder 195 , and whose second, arm 196 is hinged to cross-piece 197 . Rotation mechanism 110 is made in the form of a hinge joining second arm 196 of lever 193 to cross-piece 197 and hydraulic cylinder 198 of rotation. Disconnection mechanism 153 is made in the form of hinge joint 199 of cross-piece 197 with base 149 of soil compacting mechanism 103 and hydraulic cylinder 200 hinged to cross-piece 197 and base 149 . In this case, axis of rotation of hinge joint 199 in the nominal working position shown in FIG. 19 is located horizontally and in the transverse plane (plane of the drawing in FIG. 19 ).
Soil compacting mechanism 103 represented in FIG. 19, differs from the one described above and shown in FIG. 14 in that brackets 178 , 180 are fastened on lower plane of beam 178 of base 149 with the ability of moving them into several positions along the length of beam 178 . Hydraulic cylinders 183 are connected by hinges 201 of a standard design to additional brackets 202 made fast on upper plane of beam 178 .
It is rational to make soil compacting mechanism so that working surfaces 203 of working elements 171 in their upper position I (FIGS. 14, 19 ) were located horizontal or faced each other at angle β 1 which is not less than 90°. Furthermore, it is rational for working surfaces 203 of working elements 171 in their lower position II to be located at angle β 2 to each other, which is in the range of 60° to 120°. In addition, it is rational to assume such a ratio of the dimensions of the elements of soil compacting mechanism, that vertical displacement h 2 of working elements 171 was not less than half of diameter D of the duct, horizontal displacement L b4 was not less than half of vertical displacement h 2 and in the extreme lower position II, at least the greater part of working surface 203 of working elements 171 was located below duct 1 .
Device of monitoring and control of machine 3 is fitted with means 204 for monitoring the position of base frame 6 relative to duct 1 in the vertical and horizontal transverse directions. It is obvious that the means 204 can be made in the form of a mechanical tracking system which has means for mobile contact with the duct surface, for instance, rollers connected with displacement sensors (not shown in the drawings). Such a mechanical system, however, would be too inconvenient in service, prone to damage and different malfunctions in operation. In the preferable embodiment of the invention, means 204 is made in the form of block of receiving aerials 204 which are usually used in devices such as pipe finders, cable finders or pipeline route finders, and which use the electromagnetic field induced around the duct by alternating electric current passing through it. Block of receiving aerials 204 consists of a tubular rod 205 , at the ends of which are mounted two cases 206 with magnetic receivers which are inductance coils.
Block of receiving aerials 204 is mounted on cantilever 207 which is made fast on frame 71 of conveyor 72 , with cases 206 located symmetrical to axle 81 of soil divider 15 .
Device of monitoring and control of machine 3 is fitted with means 208 for monitoring the angle of transverse inclination of base frame 6 and means 209 of monitoring the angle of rotation of soil feeding organ 13 relative to base frame about axis 17 . The means 208 is made in the form of a unified measurement module which is applied in systems of stabilisation and control of the position of working organs of road construction machinery and is used for measurement of the angle relative to gravity vertical. Module 208 is fastened on frame of base frame close to filling equipment 9 . Means 209 is made in the form of sensor 210 of angle of rotation, which is secured on frame 19 of soil feeding organ 13 and is connected by lever 211 and hinged tie rod 212 to lifting frame 12 (FIG. 23 ).
Device for monitoring and control of machine 3 has means 213 for monitoring the position of soil compacting mechanism 103 relative to duct 1 in the vertical and horizontal transverse directions. Means 213 can be made in the form of a mechanical tracking system; proceeding from similar considerations, however, as pointed out above for means 204 , in the preferable embodiment means 213 is made similar to means 204 in the form of block of receiving aerials 213 (FIG. 21) which is mounted on base 149 with cases 206 arranged symmetrical to a vertical plane of symmetry common with the soil compacting organs 104 , 105 .
In addition, device for monitoring and control of machine 3 has means 214 for control of transverse gradient of soil compacting mechanism 103 , which is made similar to means 208 in the form of a unified measurement module for measurement of the angle relative to gravity vertical, which is mounted on base 149 .
Device for monitoring and control of machine 3 has block 215 of information processing and generation of control signals, whose data inputs are connected to the means 204 , 208 , 209 , 213 , 214 , whereas data outputs to means of indication of panels 216 , 217 of control are mounted, respectively, in cabin 218 of vehicle 6 and on remote control panel which can be located on working platform 219 . Outputs of control signals of above block 215 , are connected to electric magnets of electric hydraulic distributors which perform control of hydraulic cylinders 70 , 135 or 195 , 142 or 191 , 150 or 198 .
Device for monitoring and control of machine 3 can have system 220 for automatic control of base frame 6 , whose inputs are connected to outputs of block 215 .
Soil compacting mechanism 103 is fitted with electric system 221 for automatic reversal of hydraulic cylinders 183 , whose inputs are connected to means 222 for monitoring of, at least, upper extreme position of soil compacting organs 104 , 105 , means 223 for monitoring the highest specified pressure in the piston cavities of hydraulic cylinders 183 , and, at least, one control signal output of block 215 . Means 222 , 223 can be made in the form of a limit switch and pressure relay, respectively. Outputs of the above-mentioned system 221 are connected to electric magnets of electric hydraulic distributors of hydraulic cylinders 183 .
In a particular embodiment of machine 3 filling equipment 9 can have means 224 for soil unloading from transport organ 14 , which forms third outlet of soil. The third outlet of soil from filling equipment 9 is located with a shift towards base frame 6 relative to first two soil outlets (lower edges of trays 78 of divider 15 ). In this case, distance L b5 between vertical plane of symmetry of first two outlets of soil, to which axis 73 of duct 1 belongs, and the third soil outlet, is greater than half the width L b6 of trench 4 , and distance L b7 between third outlet of soil and longitudinal axis 11 of base frame 6 is greater than half the width L b2 of travelling unit 7 .
The means 224 can be made in the form of a working organ 225 for soil displacement across conveyor 72 located with clearance h 4 above belt 74 of conveyor 72 . The means 224 can be made in the form of an A-shaped breast (FIGS. 2, 3 ) or a flat breast mounted at an angle to conveyor 72 , or screw conveyor, or chain element (not shown in the drawings).
For adjustment of clearance h 4 , the breast is secured by means of a hinge 226 on bracket 227 of gantry 228 and is connected to gantry 228 by hydraulic cylinder 229 . Gantry 228 is fastened on frame 71 of conveyor 72 . It is preferable for electric magnets of electric hydraulic distributors of hydraulic cylinders 229 , 64 to be connected to control signal outputs of block 215 , and instead of means 222 , 223 or in addition to them, to have means 230 for monitoring the current positions of soil compacting organs 104 , 105 and means 231 for monitoring the current values of pressure in piston cavities of hydraulic cylinders 183 . The means 230 , 231 can be made in the form of displacement sensor and pressure sensor, respectively, and can be connected to data inputs of block 215 .
It is preferable for control signal outputs of block 215 to be connected to electric magnets of electric hydraulic distributors of hydraulic cylinder 200 of longitudinal feed of working elements 171 .
It is preferable for device of monitoring and control of machine 3 to have sensor 232 of path S of base frame 6 or sensor 232 of speed V of base frame 6 and timer 233 for monitoring time T of operating cycle of soil compacting mechanism 103 , which are connected to data inputs of block 215 whose control signal outputs are connected to means 234 of adjustment of the flow rate of working fluid of hydraulic cylinders 183 .
In implementation of the method of padding ground below a duct using excavated soil the appropriate apparatus made in the form of machine 3 operates as follows.
Machine 3 is placed at the end of the system of technical means (not shown in the drawings) for replacement of insulation coating of duct 1 , performed at design elevations of duct 1 in trench 4 without interruption of its operation, which in addition to machine 3 includes means for uncovering, digging under, and cleaning of duct 1 and application of new insulation coating on it (not shown in the drawings). In this case by maneuvering base frame 6 , machine 3 is positioned so that soil divider 15 and soil compacting mechanism 103 are located above duct 1 , whereas soil feeding organ 13 was located at an end face of soil dump 2 . In this case, owing to means 204 , 213 for monitoring the position of base frame 6 and soil compacting mechanism 103 relative to duct 1 being made in the form of block of receiving aerials and not requiring mechanical contact with the duct in operation, the base frame 6 can be maneuvered in a section of uncovered duct 1 behind excavated soil 2 in the automatic mode by an automatic control system 220 of base frame 6 or in the manual mode by the operator who is guided by readings of indication means of control panel 216 . After base frame 6 has been moved into the required position, filling equipment 9 is brought from the transportation position I (FIG. 1) into working position II (FIGS. 1, 2 , 3 , 5 , 6 ), lowering frame 12 by its rotation about axis 55 of hinges 56 by means of lifting hydraulic cylinders 64 ; drives 39 , 77 of soil feeding 13 and transport 14 organs are switched on and displacement of base frame 6 in the direction from the soil feeding organ 13 to soil dump 2 is begun. The soil feeding chain 18 cutters 29 loosen excavated soil 2 (or unbroken soil), and beams 27 scoop up and transport soil along breast 20 . Having passed upper edge of breast 20 , the soil under the action of the forces of inertia and gravity, moves along a curvilinear path and is lowered on the moving belt 74 of conveyor belt 72 by means of which soil is transported towards duct 1 and under the action of the forces of inertia and gravity, is discharged onto soil divider 15 . Part of soil flow falls on the left (FIGS. 3, 10 , 11 ) tray 78 , and part of the flow is stopped by cut-off shield 93 and falls on right tray 78 . The left and right soil flows under the impact of the forces of gravity, move along inclined trays 78 and having passed their lower edges are thrown into trench 4 . As distance Lb 3 between lower edges of trays 78 is greater than diameter D of duct 1 , the soil as it falls into trench 4 does not hit duct 1 , thus preventing the damage of its insulation coating which may not have a high strength in the first minutes after its application. Cut-off shield 93 oscillates under the impact of the flow of soil and springs 95 , thus reducing the amount of soil sticking to it. In order to reduce soil sticking to trays 78 and facilitate soil displacement along them, soil divider 15 can be fitted with vibrators (not shown in the drawings). For many types of soil, however, the oscillatory motions made by trays 78 under the action of unstable, variable, inertia and gravity forces on axle 81 are sufficient. In this case, in the extreme positions of trays 78 edges of slot 101 of plate 100 hitting rest 102 and shaking of trays 78 , respectively take place, thus promoting trays cleaning from soil and displacement of the latter along them. In order to achieve the required ratio of the right and left flows of soil, cut-off shield 93 (together with all of divider 15 ) by means of hydraulic cylinders 91 of regulation, is moved across the flow of soil which is thrown off conveyor 72 , thus increasing or reducing the amount of soil which is held up by cut-off shield 93 and fed onto right tray 78 . In order to increase volume Q 1 of soil which is deposited into trench 4 , soil feeding organ 13 is lowered or lifted relative to base frame 6 , respectively, turning lifting frame 12 about axis 55 of hinges 56 by means lifting hydraulic cylinders 64 . In the embodiment of machine 3 which is fitted with means 224 for unloading soil from transport organ 14 , the means 224 is used for accurate adjustment of volume Q 1 of soil deposited in the trench. For instance, to reduce volume Q 1 of soil deposited in the trench, breast 225 is lowered by means of hydraulic cylinders 229 , thus, reducing gap h 4 , so part of the soil is held up by the breast 225 , moved across the conveyor 72 and thrown off it onto the edge of trench 4 . In addition, breast 225 uniformly distributes soil across the width of belt 74 of conveyor 72 , thus increasing the accuracy and simplifying (or practically eliminating the need for) regulation of soil division by divider 15 . Availability of means 224 allows soil feeding organ 13 to be used mainly for grading ground track 16 , having largely relieved it of the function of regulation of volume Q 1 of soil deposited in the trench. Control of hydraulic cylinders 64 , 229 in regulation of the volume of soil can be carried out both in the manual and automatic modes using block 215 , as will be described further on.
After placing the soil compacting mechanism 103 over uncovered and padded with soil duct 1 , its base 149 is positioned by means of lifting-lowering mechanism 108 at a specified height H above axis 73 of duct 1 , by means of transverse displacement mechanism 109 symmetrical (transverse displacement ΔB of base 149 relative to axis 73 of duct 1 in the transverse direction is zero or is within tolerance) to longitudinal axis 73 of duct 1 and horizontally by means of mechanism of rotation 110 (angle α of skewing of base 149 relative to gravitation horizontal or vertical is zero or is within tolerance). The positioning of base 149 of soil compacting mechanism 103 by height, in the horizontal transverse direction and relative to gravity horizontal (vertical) can be performed in the manual mode by the operator, based on visual observation of soil compacting mechanism 103 and readings of the means of indication of appropriate parameters (height H, transverse displacement ΔB and angle α of skewing) of control panel 217 , or in the automatic mode by means of block 215 . In this case, block 215 , having processed the information coming from means 213 for control of the position of soil compacting mechanism 103 relative to duct 1 and means 214 for control of transverse gradient of soil compacting mechanism 103 , determines parameters H, ΔB and α, compares them with those assigned, and proceeding from the comparison results, generates at its outputs the signals for control of hydraulic cylinders 135 ( 195 ), 142 ( 191 ), 150 ( 198 ).
After the base 149 of soil compacting mechanism 103 has been positioned as required, the power drive 169 of soil compacting organs 104 , 105 is switched on. In this case hydraulic cylinders 183 perform cyclic drawing out and in of the rod, while working elements 171 perform downward cyclic movement from upper position I (FIGS. 14, 19 ) into lower position II towards each other with simultaneous rotation, decreasing the angle β from β 1 value to β 2 value and vice versa from position II into position I. Reversal of hydraulic cylinders 183 is performed by electric system 221 when working elements 171 are placed into the upper I and lower II positions or assigned pressure P max of working fluid is achieved in the piston cavities of hydraulic cylinders 183 . When at least one of parameters H, ΔB, α goes beyond the tolerance or in the case of their inadmissible combination, block 215 generates a signal for switching off power drive 169 (of hydraulic cylinders 183 ), stopping the base frame 6 and giving an audible signal.
Disconnection mechanism 153 (FIGS. 1, 14 , 18 ) operates as follows. When working elements 171 are lowered as a result of their interaction with the soil being compacted, the movement of elements 171 relative to soil in the direction of displacement of base frame 6 under the action of the force of adhesion of elements 171 to the soil stops, and rotation in hinge 154 through angle y, and displacement of elements 171 relative to base frame 6 in the direction opposite to its displacement direction into the rear position I (FIG. 1) takes place. After completion of soil compacting at the start of lifting of elements 171 , when the force of their adhesion to the soil becomes small enough, the hinge 154 rotates in the reverse direction under the action of gravity forces and forces of compression of springs 163 of shock absorbers 157 , and elements 171 move relative to the soil and base frame 6 in its displacement direction, i.e. longitudinal feed of elements 171 occurs. In this case, shock absorbers 157 can be adjusted in such a way that in the front position II (FIG. 1 ), the soil compacting mechanism 103 with arm 138 and shackle 155 will be located in the vertical plane or in such a way that they will deviate forward from the vertical by angle γ 2 which can be equal to angle γ 1 . In an embodiment of disconnection mechanism 153 (FIG. 19 ), longitudinal feed of working elements 171 is performed at the required moment by hydraulic cylinder 200 . In this case, the soil compacting can be performed without lifting working elements 171 in their lower position II above level 235 of soil deposition in trench 4 . However, lifting of elements 171 in their upper position I above level 235 of soil in the trench, and their longitudinal feed in exactly this position, are rational to prevent their moving so along the duct and possible resultant damage of the insulation coating by rather large and sharp stones or other inclusions present in the soil.
Now let us consider the process of soil compacting in more detail. It is possible to achieve sufficient compacting of the soil below duct 1 with sufficiently soft impact of the soil being compacted on the surface of the insulation coating, by plane-parallel displacement of elements 171 along a rectilinear trajectory inclined at a small enough angle to the horizon, for instance 45°. In order to implement it, in soil compacting mechanism 103 it is enough for fourth hinge 177 -to be shifted relative to second hinge 174 in the horizontal direction towards connecting rod 170 , and for the straight lines passing through the centers of hinges 173 , 174 , 176 , 177 , to form a parallelogram. It is, however, impossible to be implemented in narrow trench 4 in view of lack of space. Therefore, for narrow trenches it is rational and sufficient for the spacing of first 173 and third 176 hinges to be greater than the spacing of second 174 and fourth hinges 177 and/or spacing of third 176 and fourth 177 hinges to be greater. than the spacing of first 173 and second 174 hinges. This allows displacement of working elements 171 along a curvilinear trajectory with their simultaneous rotation and fitting into the overall dimensions of narrow trench 4 . In the shown in the drawings embodiment of soil compacting mechanism 103 , elements 171 in the upper part of the trajectory mainly move in the vertical direction, with an angle β 1 between their working surfaces 203 large enough to prevent displacement of soil along working surfaces 203 towards duct 1 or damage of its insulation coating by soil. In the lower part of the path, elements 171 move mainly in the horizontal direction, within angle β 2 between their working surfaces, that on the one hand, should be small enough to provide for soil compacting directly below duct, and on the other hand, a too great reduction of angle β 2 is not rational because of concurrent increase of angle φ of slope of the compacted zone of soil and possibility of its breaking up when duct 1 rests against it. Proceeding from these considerations, it is rational for angle φ to be approximately equal to the angle of the natural sloping of soil, and, therefore, angle β 2 =2×(90°−φ). In the opinion of the authors, the following values of angles β 1 and β 2 satisfy the above conditions: β 1 ≧90°; 60°≦β 2 ≦120°.
In order to ensure soil compacting along the entire height h 3 of the space below a duct, which can be of the order of 0.8 m, lifting of elements 171 in their upper position I above level 235 of soil in the trench and location of the greater part of working surface 203 of elements 171 in their lower position II below duct 1 , it is necessary for vertical displacement h 2 of soil compacting elements to be not less than half of diameter D of duct 1 . For soil compacting directly below duct 1 it is rational for horizontal displacement Lb 4 of elements 171 to be not less than half of vertical displacement h 2 .
Model investigations of soil compacting mechanism were performed for compacting loam soil below a duct of diameter D=1220 mm at a height h 3 =0.84 m with the following values of soil compacting mechanism parameters: h 2 =0.8 m, L b4 =0.64 in, β 1 =140°, β 2 =90°. As a result, it was found that the claimed soil compacting mechanism is characterised by insignificant forces on working elements 171 due to coincidence of their movement direction and the required direction of soil deformation. So, applying to each element 171 force R equal to 4 tons, it is possible to achieve bed coefficient Ky equal to 1 MN/m 3 with specific pitch of compacting (determined as the ratio of pitch L at , of longitudinal feed of elements 171 to their length L, measured along duct axis) t=1.1-1.2. Power consumption in such a compacting mode at the speed of displacement along the duct V=100 m/h is 12 to 15 KW (not taking into account the efficiency factor of the hydraulic drive and soil compacting mechanism 103 ). Due to the presence of disconnection mechanism displacement of soil compacting mechanism requires the pulling force of not more than 1 to 2 tons.
If in the upper position, elements 171 are completely withdrawn from the soil, the level of filling trench 4 with soil should be not arbitrary, but strictly specified and adjusted so that at the moment when pressure P max is reached in the piston cavities of hydraulic cylinders, at which force R max on elements 171 is equal to the design value, elements 171 did not quite reach extreme lower position II and besides that were in a certain optimal design position relative to the duct. If at the moment of the pressure in hydraulic cylinders 183 rising up to P max , elements 171 will be significantly short of lower position II, i.e. they will be located higher than the above design position, the degree of soil compacting below a duct will decrease, here in order to restore the degree of soil compacting, it is necessary to reduce volume Q 1 of soil deposited into the trench. If elements 171 come to the extreme lower position II at a pressure lower than P max , the degree of soil compacting will also become smaller, in this case volume Q 1 of soil deposited in the trench should be increased to restore the degree of soil compacting. In order to provide the appropriate regulation of volume Q 1 of soil deposited into the trench, it is preferable for machine 3 to have displacement sensor 230 and pressure sensor 231 , the information from which comes to the input of block 215 , having processed which (preferably taking into account the information of means 213 ) block 215 determines the position of working elements 171 at the moment pressure P max is reached and compares it with the required pressure. Proceeding from the results of comparison, block 215 generates at its outputs the signals which can be sent to the appropriate means of indication of panel 216 or to the electric magnets of electric hydraulic distributors of hydraulic cylinders 64 , 229 in the automatic control mode.
If the disconnection mechanism 153 incorporates a hydraulic cylinder 200 (FIG. 19) for a forced longitudinal feed of elements 171 , and displacement sensor 230 and pressure sensor 231 are available, control of filling 9 and compacting 10 equipment can be performed as follows. In this case filling equipment 9 feeds soil into trench in an excess amount, whereas volume Q 2 (Q 2 ≦Q 1 ) of soil which undergoes compacting, is regulated by increasing or decreasing height h 2 of lifting of elements 171 and providing their forced longitudinal feed by hydraulic cylinder 200 , when they are lowered into the soil. The soil left above elements 171 is not used during compacting. In this case block 215 having processed the information of sensors 230 , 231 (preferably taking into account information of means 213 ) determines the required (design) upper position of elements 171 and at the moment when elements 171 reach the upper design position, generates at its outputs the signals for stopping hydraulic cylinders 183 and switching on hydraulic cylinder 200 for longitudinal feed of elements 171 . Reversal of hydraulic cylinders 200 , 183 can be performed independently by electric system 221 .
The degree of soil compacting under a duct, characterised by bed coefficient K y , depends on the greatest force R max on elements 171 , which is determined by pressure P max in piston cavities of hydraulic cylinders 183 , and on specific pitch of compacting t which is determined by path S or speed V of displacement of base frame 6 along duct 1 and duration of time T of operation of soil compacting mechanism, i.e. t=L at /L al =S/L al =V×T/L al . Machine 3 moves in synchronism with other machinery of the system for replacement of insulation coating of a duct, i.e. its speed V can change for reasons independent of it. Therefore, in order to ensure a constant bed coefficient K y it is rational to envisage in the device for monitoring and control of the machine the capability of regulation of specific pitch of compacting t and/or maximal pressure P max in hydraulic cylinders 183 . Thus, it is rational for reversal of hydraulic cylinders 183 to be performed by signals of block 215 which having processed the information of sensor 232 of speed V or path S covered by base frame 6 during time T, which path is equal to pitch L at of longitudinal feed of elements 171 , will assign the required ratio of parameters t and P max Here block 215 can allow for angle φ 1 of skewing of base frame 6 relative to gravity vertical, which is entered into it from appropriate device 204 so that in the case of skewing of base frame 6 towards trench 4 pressure P max can be increased with a simultaneous increase of pitch t, and in the case of skewing of base frame 6 in the opposite direction P max can be lowered with a simultaneous reduction of pitch t.
Extremely important is the fact that machine 3 prepares itself the path for displacement of travelling unit 7 of base frame 6 over it. The soil surface can have unevenness (pits, mounds, etc.), riding over which of travelling unit 7 can lead to an abrupt skewing of base frame 6 , displacement of soil compacting mechanism 103 from the set position relative to duct 1 , which cannot be compensated by mechanisms of lifting-lowering 108 , transverse displacement 109 or rotation 110 . which may lead to damage of duct 1 or of its insulation coating, and in the best case to stoppage of machine 3 , and with it the entire system of machinery for replacement of the insulation coating. In the claimed method of padding ground below a duct such a situation is impossible, as travelling unit 7 of base frame 6 moves over the surface of ground path 16 which is formed by soil feeding organ 13 when feeding excavated soil 2 . In this case mounds are cut off by soil feeding organ, and pits remain filled with excavated soil 2 . In addition, by means of skewing of soil feeding organ about axis 17 , machine 3 is capable of providing the required transverse gradient of path 16 , in order to maintain a stable horizontal position of base frame 6 in the transverse plane, and thereby create favourable conditions for operation of compacting equipment 10 , also in areas with a considerable transverse gradient. As trench 4 is filled with soil not completely, part of excavated soil 2 remains, and it can be used for forming even and horizontal in the transverse direction path 16 , this being especially beneficial in an area with considerable unevenness of the soil or with its considerable transverse gradient. However, as a result of movement of travelling unit 7 over a layer of loose excavated soil 2 , skewing of base frame 6 may occur, because of a non-uniform subsidence of soil under the right and left caterpillars of travelling unit 7 , this being promoted by cyclic variation of the ratio of bearing pressure in the right and left caterpillars as a result of operation of soil compacting mechanism. In this case, by appropriate skewing of the soil compacting organ 13 relative to the base frame 6 , path 16 is formed with a transverse gradient which is opposite in direction and equal in value to skewing of base frame 6 as a result of non-uniform subsidence of soil under the right and left caterpillars. Likewise, it is possible to maintain a stable position of base frame 6 in movement of travelling unit 7 over any soil with a low load-carrying capacity, and compensate for the adverse influence of soil compacting mechanism 103 . Control of skewing of soil feeding organ 13 can be performed either in the manual mode by the operator by the readings of the means of indication of angle φ 1 of base frame 6 skewing relative to gravity vertical; and angle φ 2 of skewing of soil feeding organ relative to base frame 6 , which are located on panel 216 , or in the automatic mode by means of block 215 which forms at its outputs the signals of control of hydraulic cylinders 70 of rotation. In this case, angle φ 2 of skewing of soil feeding organ 13 relative to base frame 6 is initially set to be opposite in direction and equal in value to angle of skewing of base frame 6 . If after a certain lapse of time angle φ 1 does not start decreasing, angle φ 2 increased up to the value at which decrease of angle φ 1 is found, and after straightening of base frame 6 (at φ 1 =0) angle φ 2 is reduced to the previous value at which a stable position of base frame 6 was preserved.
For optimal operation of compacting equipment 10 , it should be located strictly in the transverse plane (normal to the direction of displacement of base frame 6 ). The position of compacting equipment 10 is regulated by adjustment of the position of bracket 114 relative to gantry 118 . In this case, nuts 120 and bolts 129 are loosened, toothed quadrant 126 of plate 125 is brought out of engagement with toothed quadrant 131 of base plate 115 of bracket 114 , and bracket 114 is rotated about axis 123 of pin 116 through the required angle, in keeping with scale 130 . After that, toothed quadrant 126 is bought into engagement with toothed quadrant 131 and bolts 129 and nuts 120 are tightened. | The present invention relates to a method for padding ground below a duct ( 1 ) using excavated soil ( 2 ), wherein said method uses a vehicle ( 6 ) that comprises a soil feeding organ ( 13 ), a transport organ ( 14 ) and soil compacting organs ( 104, 105 ). The vehicle moves along a ground path ( 16 ) which is formed by the soil feeding organ ( 13 ) as it collects excavated soil ( 2 ). This method allows for a reliable orientation of the soil compacting organs ( 104, 105 ) relative to the duct ( 1 ), wherein said compacting organs apply a force on the soil previously deposited in the trench ( 4 ). This invention also relates to a device which is used for padding ground below a duct ( 1 ) and comprises a device ( 106 ) for hanging a soil-compacting mechanism ( 103 ) to the vehicle ( 6 ). The device ( 106 ) includes a disconnection mechanism ( 153 ) that enables the cyclic displacement of the rammer-type compacting organs ( 104, 105 ) in the displacement direction of the vehicle ( 6 ). When compacting soil, the working members ( 171 ) of the compacting organs ( 104, 105 ) are capable of cyclic downward displacement towards each other while simultaneously rotating in a direction in which the angle they define becomes smaller. This system may be used for efficiency compacting soil below a duct ( 1 ) while minimising the stress applied by the soil to the surface of said duct ( 1 ). | 4 |
BACKGROUND OF THE INVENTION
The invention is directed towards the common issues with current designs of cabinetry and Ready To Assemble furniture known as RTA furniture.
The current large RTA furniture designs such as a desk are heavy and densely packaged in a single box that is difficult to transport for the consumer from point of purchase to the desired location.
The current large RTA furniture designs contain a large assortment of different assembly parts that require a considerable amount of time and area to assemble. The large assortment of parts increase the level of difficulty of the furniture assembly.
The current cabinetry and RTA furniture designs are comprised of compressed particles of wood and adhesive covered by a veneer surface that warp, weaken and disintegrate over time when it comes in contact with water or moisture.
The current RTA furniture designs require you to use a glue or adhesive that makes disassembly nearly impossible without damaging the furniture.
The current large RTA designs that are fully assembled are difficult to move from one area to another. The weight of the furniture is too heavy for the assembly joints. Typically the joints of the furniture crack or become damaged. The broken furniture is then considered undesirable and not repairable by the consumer and discarded into our landfills.
The current RTA designs have square sharp edges which are dangerous for children. A child or adult head can be seriously injured if he or she falls and their head comes in contact this edge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Note: An axis block is placed with each figure to assist the viewer determine the viewing angle. Each axis block is marked on opposite sides X, Y and Z corresponding to the figures axis. The X axis is referring to left and right. The Y axis is referring to front and back. the Z axis is referring to top and bottom.
Referring now to FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts the Panel edge 1 contains segment(s) 1 A and Panel edge tab 1 B. The Panel edge 1 can be made from a single piece of material or multiple pieces of material.
In further detail, to FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts six views of Panel edge 1 , depicting the basic shape.
In further detail, FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts the Panel edge segment(s) 1 A. The number of segments and distance between them can be varied for appearance, use of spacers, construction and/or manufacturing benefits.
In further detail, FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts the Panel edge segment(s) are spaced apart equally the same width as the segment(s) width. This equal spacing allows the Panel edge segment to interconnect or mesh with an inverted Panel edge with identical spacing which is further discussed in pages 6 and 7 .
In further detail, FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts the Panel edge segment(s) are spaced apart equally the same width as the segment(s) width. The Panel edge segment(s) 1 A, size, width and spacing can vary on Panel edge 1 but must correspond to the size, width and spacing of an inverted interconnecting or meshing segments of another Panel edge 1 .
In further detail, FIGS. 1 , 2 , 3 , 4 , 5 and 6 , depicts Panel edge tab 1 B. The dimensions are dependent on the construction or design desired of the finished product.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 7 and 8 , depicts two different views of an unassembled Panel 7 .
In further detail, FIGS. 7 and 8 , depicts that Panel edge 1 , Panel edge 2 , Panel face 3 , Panel face 4 and Panel separator(s) 5 make up Panel 7 .
In further detail, FIGS. 7 and 8 , depicts that Panel edge 1 and 2 being similar in shape.
In further detail, FIGS. 7 and 8 , depicts that the panel edge 1 and 2 are aligned on the Y-axis but separated on the Y-axis to allow Panel face 3 and 4 to be placed on each opposite side of the Panel edge tab 1 B and 2 B.
In further detail, FIGS. 7 and 8 , depicts that the Panel edge 2 is aligned with Panel edge 1 on the Y-axis and Panel edge 2 is rotated approximately 180 degrees on the X-axis in reference to panel edge 1 .
In further detail to FIGS. 7 and 8 , depicts Panel edge 1 and 2 are separated on the Y-axis. The dimension of this separation is dependent on the Y-axis dimension of the Panel face 3 and 4 .
In further detail to FIGS. 7 and 8 , depicts Panel face 3 and 4 . The physical dimensions of Panel face 3 and 4 are dependent only on the desired construction and/or design.
In further detail to FIGS. 7 and 8 , depicts Panel Separator 5 that will provide support and separation between Panel face 3 and 4 . The number of panel separators and positioning is dependent on the construction and/or desired design.
Referring now to FIGS. 9 and 10 , depicts two different views of Panel 7 assembled
In further detail to FIGS. 9 and 10 , depicts the Panel face 3 and 4 are assembled on the opposite sides of Panel edge tab 1 B and 2 B.
In further detail to FIGS. 9 and 10 , depicts the Panel separator 5 is equal in the X-axis dimension to the X-axis dimension of Panel edge tab 1 B and 2 B.
In further detail to FIGS. 9 and 10 , the Panel support 5 and the Panel edge 1 and 2 can be secured to the Panel face 3 and 4 by adhesive, chemical or natural bonding or by mechanical means or any combination of the aforementioned means of securement.
In further detail to FIGS. 9 and 10 , depicts Panel void 6 , which is the separation area between the Panel face 3 and 4 . The purpose of this void is further detailed in FIGS. 22 and 23 .
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 11 , 12 and 13 , depicts the cap edge 8 includes components Cap edge group 8 A, Cap edge face 8 B and 8 C, Cap edge tab 8 D and Cap edge cutout 8 E and 8 F.
In further detail to FIGS. 11 , 12 and 13 , depicts Cap edge group 8 A having opposing mitered edges Cap edge face 8 B and 8 C.
In further detail to FIGS. 11 , 12 and 13 , depicts Cap edge tab 8 D protrudes from cap edge group 8 A on the Y axis.
In further detail to FIGS. 11 , 12 and 13 , depicts cap edge tab cutouts 8 E, 8 F on opposite ends on the X axis and opposite sides of the Cap edge tab 8 D on the Z axis.
Referring now to FIGS. 14 and 15 , depicts the Cap edge 8 and that Cap edges 9 , 10 and 11 are identical in shape and size to cap edge 8 in FIGS. 11 , 12 and 13
In further detail to FIGS. 14 and 15 , depicts the cap edges 8 , 9 , 10 and 11 are placed so that the corners are adjacent to each other and spaced apart from each other on the X-Y axis plane.
In further detail to FIGS. 14 and 15 , depicts the cap edges 8 , 9 , 10 and 11 are aligned on the X-Y axis plane.
Referring now to FIGS. 16 and 17 , depicts the cap edges 8 , 9 , 10 and 11 assembled on the X-Y axis plane resulting in cap edge group 12 .
In further detail to FIGS. 16 and 17 , depicts the cap edges 8 and 9 assembled so that cap edge face 8 C is assembled or faced with the adjacent face 9 B resulting in an outside corner.
In further detail to FIGS. 16 and 17 , depicts the cap edges 9 and 10 assembled so that cap edge face 9 C is assembled or faced with the adjacent face 10 B resulting in an outside corner.
In further detail to FIGS. 16 and 17 , depicts the cap edges 10 and 11 assembled so that cap edge face 10 C is assembled or faced with the adjacent face 11 B resulting in an outside corner.
In further detail to FIGS. 16 and 17 , depicts the cap edges 11 and 8 assembled so that cap edge face 11 C is assembled or faced with the adjacent face 8 B resulting in an outside corner.
In further detail to FIGS. 16 and 17 , depicts the cap edges 8 and 9 interconnected by the overlapping of the Cap edge cutouts 8 F and 9 E resulting in an inside corner edge.
In further detail to FIGS. 16 and 17 , depicts the cap edges 9 and 10 interconnected by the overlapping of the Cap edge cutouts 9 F and 10 E resulting in an inside corner edge.
In further detail to FIGS. 16 and 17 , depicts the cap edges 10 and 11 interconnected by the overlapping of the Cap edge cutouts 10 F and 11 E resulting in an inside corner edge
In further detail to FIGS. 16 and 17 , depicts the cap edges 11 and 8 interconnected by the overlapping of the Cap edge cutouts 11 F and 8 E resulting in an inside corner edge.
In further detail to FIGS. 16 and 17 , depicts that mating the cap edges 8 , 9 , 10 and 11 creates Cap edge group 12 a.
In further detail to FIGS. 16 and 17 , depicts that Cap edge group 12 A is a square type frame with a recessed inside edge on both sides of the frame on the Z axis.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIG. 18 depicts an angled view of the unassembled Cap 16 which is made up of components, cap panels 13 A and 13 B, cap edge group 12 and cap separator 14 .
In further detail to FIG. 18 depicts cap Separator 14 , this is placed on the Panel face 13 B and will provide support and separation between the Cap face 13 A and 13 B. The number of panel separators and positioning is dependent on the desired structural design.
In further detail to FIG. 18 , depicts the cap panel 13 A, cap edge group 12 and cap panel 13 B centered on the Z axis but spaced apart on the Z axis.
In further detail to FIG. 18 depicts cap Separator 14 providing support and separation between the Cap face 13 A and 13 B.
Referring now to FIG. 19 depicts a frontal view of the same items as item 18 with the cap edge 9 and 11 removed to better depict where the cap panels 13 A and 13 B are to be positioned on the cap edge tabs 8 D and 10 D.
Referring now to FIG. 20 depicts an angled view that cap panels 13 A and 13 B, cap edge group 12 and cap separator 14 assembled create Cap 15 .
In further detail to FIG. 20 depicts the Cap panel 13 A is positioned on the top inside recessed edge of Cap edge group 12 .
In further detail to FIG. 20 depicts the Cap panel 13 B is positioned on the bottom inside recessed edge of Cap edge group 12 .
In further detail to FIG. 20 , the Cap panels 13 A and 13 B can be secured to the Cap edge group 12 by adhesive, chemical or natural bonding or by mechanical means or any combination of the aforementioned means of securement.
Referring now to FIG. 21 , depicts a frontal view of the same items as item 18 with the cap edge 9 and 11 removed to better depict how the cap face 13 A and 13 B are positioned on the cap edge tabs 8 D and 10 D.
In further detail to FIG. 21 , depicts cap Separator 14 between cap face 13 A and 13 B, this provides support and separation between the Cap face 13 A and 13 B. The number of panel separators and positioning is dependent on the desired design.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 22 and 23 , depicts two views of panel 7 being filled with a foam polymer or similar material into the panel void 6 opening of panel 7 . The foam type polymer will act as an adhesive to the inside surfaces of panel 7 and when dried the foam cell structure will provide internal support for the panel 7 , The foam polymer or similar material can be inserted into the void 6 instead as a solid mass and adhered to the inside surfaces by a glue or adhesive.
Referring now to FIGS. 24 and 25 , depicts two views of panel void access hole 18 . Panel void access hole 18 was created to provide external access to the Cap void 16 . In further detail, to FIGS. 24 and 25 , depicts two views of panel void access holes 18 . The arrangement and size can be based on material inserted into Cap void 16 . The number of holes is dependent on the material to provide expansion relief.
In further detail, FIGS. 24 and 25 , depicts two views of cap 15 being filled with a foam polymer or similar material through the opening of panel void access hole 18 . The foam type polymer will act as an adhesive to the inside surfaces of cap 13 A and when dried the foam provides adherence and/or internal support for the cap 13 , The foam can be inserted into the void as a solid mass and adhered to the inside surfaces by a glue or adhesive.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 26 and 27 , depicts two views of panel 7 , panel edge and panel edge cover 20 .
Referring now to FIGS. 28 and 29 , depicts two views of 19 and panel edge cover 20 assembled together resulting in panel corner 21 .
In further detail, FIGS. 28 and 29 , depicts two views of panel corner group 21 and panel 7 unassembled.
Referring now to FIGS. 30 and 31 , depicts two views of panel corner group 21 and panel 7 assembled by aligning the interconnecting segments of panel 7 and panel corner group 21 .
In further detail FIGS. 30 and 31 , the positioning lines for mating the segments of panel corner group 21 and panel 7 resulting in a solid corner.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 32 and 33 , depicts two views of panel 7 , panel 7 A and Panel corner group 21 and cap corner group 21 A unassembled.
In further detail FIGS. 32 and 33 , depicts the mating lines of panel 7 and panel corner group 21 and the mating lines of panel 7 A and panel corner group 21 A.
Referring now to FIGS. 34 and 35 , depicts two views of panel 7 , panel 7 A, panel 7 B and cap corner edge group 21 and cap corner edge group 21 A.
In further detail FIGS. 34 and 35 , depicts the mating of panel 7 and panel corner group 21 and the mating of panel 7 A and panel corner group 21 A.
In further detail FIGS. 34 and 35 , depicts the mating of panel 7 and panel corner group 21 results in panel corner group 22 .
In further detail FIGS. 34 and 35 , depicts the mating of panel 7 A and panel corner group 21 A results in panel corner group 22 A.
In further detail FIGS. 34 and 35 , depicts the mating lines of panel 7 B with panel corner group 22 and panel corner group 22 A.
Referring now to FIGS. 36 and 37 , depicts panel 7 B assembled with panel corner group 22 and panel corner group 22 A.
In further detail FIGS. 36 and 37 , depicts panel 7 B, panel corner group 21 A and panel corner 22 A results in panel group 23 .
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 38 and 39 , depicts two views of panel group 23 , corner edge 24 a , 24 b , 24 c , 24 d blackened and dotted along the Z axis of the panel group 23 and centerline marks 25 a , 25 b , 25 c , 25 d.
In further detail FIGS. 38 and 39 , depicts the corner edges 24 a , 24 b , 24 c , 24 d blackened and arced and extend the length of the panel group 23 marked by dotted lines.
In further detail FIGS. 38 and 39 , depicts the centerline marks 25 a , 25 b , 25 c , 25 d centered on the Z-axis of each Panel edge segment of panel group 23 .
Referring now to FIGS. 40 and 41 , depicts two views of panel group 23 showing the outer corner edge radius 24 a , 24 b , 24 c , 24 d were subtracted from the Panel group 23 due to the material being excessive and unnecessary to the strength of the structure resulting in lighter edges.
In further detail FIGS. 40 and 41 , depicts the Edge hole circle 26 a , 26 b , 26 c , 26 d to be subtracted which is centered on a centerline. Each hole will extend through the length of the panel group 23 along the Z-axis.
Referring now to FIGS. 42 and 43 , depicts two views of panel group 23 displaying that Edge holes 27 a , 27 b , 27 c , 27 d were subtracted the entire length of the Panel.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 44 and 45 depicts two views of rod 28 A aligned directly above the centerline on the Z-axis of the Edge hole 27 a of panel group 23 .
In further detail FIGS. 44 and 45 depicts two views of rod 28 B each aligned directly above the centerline on the Z-axis of the Edge hole 27 b of panel group 23 .
In further detail FIGS. 44 and 45 depicts two views of rod 28 C each aligned directly above the centerline on the Z-axis of the Edge hole 27 c of panel group 23 .
In further detail FIGS. 44 and 45 depicts two views of rod 28 D each aligned directly above the centerline on the Z-axis of the Edge hole 27 d of panel group 23 . Referring now to FIGS. 46 and 47 depicts two views of rod 28 A aligned on the centerline on the Z-axis and inserted fully through Edge hole 27 a of panel group 23 . In further detail FIGS. 46 and 47 depicts two views of rod 28 B aligned on the centerline on the Z-axis and inserted fully through Edge hole 27 b of panel group 23 . In further detail FIGS. 46 and 47 depicts two views of rod 28 C aligned on the centerline on the Z-axis and inserted fully through Edge hole 27 c of panel group 23 . In further detail FIGS. 46 and 47 depicts two views of rod 28 D aligned on the centerline on the Z-axis and inserted fully through Edge hole 27 d of panel group 23 In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 48 and 49 depicts cap 15 A centered directly above the Panel edge body 23 and cap 15 B centered directly below the Panel edge body 23 on the Z-axis.
In further detail, FIGS. 48 and 49 depicts the Cap edge hole 29 A, 29 B, 29 C, 29 D, each hole created in Cap 15 A and Cap 15 B are on the same Z-axis centerline of each corresponding rod 28 A, 28 B, 28 C and 28 D. The term Corresponding is referring to having the same suffix letter as itself.
In further detail, FIGS. 48 and 49 depicts the Cap edge hole 29 A, 29 B, 29 C, 29 D, each hole created in Cap 15 A is slightly larger than each corresponding rod 28 A, 28 b , 28 C and 28 D on the Z-axis.
In further detail, FIGS. 48 and 49 depicts the Cap edge hole 29 E, 29 F, 29 G, 29 H, each hole created in Cap 15 B is slightly larger than each corresponding rod 28 A, 28 B, 28 C and 28 D on the Z-axis.
Referring now to FIGS. 50 and 51 depicts Panel edge body 23 assembled with Cap 15 A by inserting the rod 28 A, 28 B, 28 C and 28 D through each corresponding Cap edge hole 29 A, 29 B, 29 C, 29 D.
In further detail, FIGS. 50 and 51 depicts Panel edge body 23 assembled with Cap 15 B by inserting the rod 28 A, 28 B, 28 C and 28 D through each aligned Cap edge hole 29 E, 29 F, 29 G, 29 H.
In further detail, FIGS. 50 and 51 depicts the end of each rod 28 A, 28 B, 28 C, 28 D extended through the corresponding Cap edge hole 29 A, 29 B, 29 C, 29 D.
In further detail, FIGS. 50 and 51 depicts the end of each rod 28 A, 28 B, 28 C, 28 D extended through the corresponding Cap edge hole 29 E, 29 F, 29 G, 29 H.
In further detail, FIGS. 50 and 51 depicts the Main body 30 contains rod 28 A, 28 B, 28 C, 28 D, Cap 15 A and 15 B and Panel edge body 23 .
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 52 and 53 depicts Corner cap nuts 31 A, 31 B, 31 C, 31 D each aligned on the centerline of each corresponding Rod 28 A, 28 B, 28 C, 28 D of the Z-axis.
In further detail, FIGS. 52 and 53 depicts Corner cap nuts 31 A, 31 B, 31 C, 31 D having a mating thread identical to Rod 28 A, 28 B, 28 C, 28 D.
Referring now to FIGS. 54 and 55 depicts Corner cap nuts 31 A, 31 B, 31 C, 31 D each threaded onto the corresponding Rod 28 A, 28 B, 28 C, 28 D.
In further detail, FIGS. 54 and 55 the Rods 28 A, 28 B, 28 C, 28 D extend through the Cap edge holes 29 A, 29 B, 29 C, 29 D.
In further detail, the components on this page can be constructed from any material, natural or synthetic that is suitable for the desired design of the product such as wood, wood by-product or plastic.
In further detail of this page, all dimensions are dependent on the desired final construction and/or design.
Referring now to FIGS. 56 and 57 depicts Foot 32 A, 32 B, 32 C, 32 D each aligned on the centerline of each corresponding Rod 28 A, 28 B, 28 C, 28 D.
In further detail, FIGS. 56 and 57 depicts Corner cap nuts 31 A, 31 B, 31 C, 31 D having a mating thread identical to Rod 28 A, 28 B, 28 C, 28 D.
Referring now to FIGS. 58 and 59 depicts Corner cap nuts 31 A, 31 B, 31 C, 31 D each threaded onto the corresponding Rod 28 A, 28 B, 28 C, 28 D.
Referring now to FIG. 60 , 61 , 62 , 63 showing completed assembly 33 .
DRAWINGS SHORT DESCRIPTION
FIG. 1 is a side view of a Quick assembling Furniture assembly
FIG. 2 is a front view of a Quick assembling Furniture assembly
FIG. 3 is a top view of a Quick assembling Furniture assembly
FIG. 4 is a bottom view of a Quick assembling Furniture assembly
FIG. 5 is a perspective view of a Quick assembling Furniture assembly
FIG. 6 is a perspective of a Quick assembling Furniture assembly
FIG. 7 is a perspective view of a Quick assembling Furniture assembly
FIG. 8 is a top view of a Quick assembling Furniture assembly
FIG. 9 is a perspective view of a Quick assembling Furniture assembly
FIG. 10 is a top view of a Quick assembling Furniture assembly
FIG. 11 is a front view of a Quick assembling Furniture assembly
FIG. 12 is a top view of a Quick assembling Furniture assembly
FIG. 13 is a side view of a Quick assembling Furniture assembly
FIG. 14 is a top view of a Quick assembling Furniture assembly
FIG. 15 is a top view of a Quick assembling Furniture assembly
FIG. 16 is a perspective view of a Quick assembling Furniture assembly
FIG. 17 is a perspective view of a Quick assembling Furniture assembly
FIG. 18 is a perspective view of a Quick assembling Furniture assembly
FIG. 19 is a perspective view of a Quick assembling Furniture assembly
FIG. 20 is a front view of a Quick assembling Furniture assembly
FIG. 21 is a front view of a Quick assembling Furniture assembly
FIG. 22 is a side view of a Quick assembling Furniture assembly
FIG. 23 is a top view of a Quick assembling Furniture assembly
FIG. 24 is a perspective view of a Quick assembling Furniture assembly
FIG. 25 is a perspective view of a Quick assembling Furniture assembly
FIG. 26 is a perspective view of a Quick assembling Furniture assembly
FIG. 27 is a perspective view of a Quick assembling Furniture assembly
FIG. 28 is a perspective view of a Quick assembling Furniture assembly
FIG. 29 is a top view of a Quick assembling Furniture assembly
FIG. 30 is a top view of a Quick assembling Furniture assembly
FIG. 31 is a top view of a Quick assembling Furniture assembly
FIG. 32 is a perspective view of a Quick assembling Furniture assembly
FIG. 33 is a top view of a Quick assembling Furniture assembly
FIG. 34 is a perspective view of a Quick assembling Furniture assembly
FIG. 35 is a top view of a Quick assembling Furniture assembly
FIG. 36 is a perspective view of a Quick assembling Furniture assembly
FIG. 37 is a top view of a Quick assembling Furniture assembly
FIG. 38 is a perspective view of a Quick assembling Furniture assembly
FIG. 39 is a top view of a Quick assembling Furniture assembly
FIG. 40 is a perspective view of a Quick assembling Furniture assembly
FIG. 41 is a top view of a Quick assembling Furniture assembly
FIG. 42 is a perspective view of a Quick assembling Furniture assembly
FIG. 43 is a front view of a Quick assembling Furniture assembly
FIG. 44 is a perspective view of a Quick assembling Furniture assembly
FIG. 45 is a front view of a Quick assembling Furniture assembly
FIG. 46 is a perspective view of a Quick assembling Furniture assembly
FIG. 47 is a front view of a Quick assembling Furniture assembly
FIG. 48 is a perspective view of a Quick assembling Furniture assembly
FIG. 49 is a front view of a Quick assembling Furniture assembly
FIG. 50 is a perspective view of a Quick assembling Furniture assembly
FIG. 51 is a front view of a Quick assembling Furniture assembly
FIG. 52 is a perspective view of a Quick assembling Furniture assembly
FIG. 53 is a front view of a Quick assembling Furniture assembly
FIG. 54 is a perspective view of a Quick assembling Furniture assembly
FIG. 55 is a front view of a Quick assembling Furniture assembly
FIG. 56 is a perspective view of a Quick assembling Furniture assembly
FIG. 57 is a front view of a Quick assembling Furniture assembly
FIG. 58 is a perspective view of a Quick assembling Furniture assembly
FIG. 59 is a front view of a Quick assembling Furniture assembly
FIG. 60 is a perspective view of a Quick assembling Furniture assembly
FIG. 61 is a side view of a Quick assembling Furniture assembly | The invention is directed to furniture such as of floor independently standing or wall mounted furniture, cabinetry, containers, boxes that can be lightweight, modular, easily assembled and disassembled. | 8 |
PRIORITY CLAIM
[0001] This application is a continuation of U.S. Patent Application Ser. No. 10/131,980, filed Apr. 25, 2002, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of implantable medical devices, and more particularly to a medical electrical lead providing improved implantation capabilities.
BACKGROUND OF THE INVENTION
[0003] Electrical stimulation of electrically excitable tissue such as the brain and/or nerve tissue of the spinal cord or peripheral nerve can result in pain reduction and/or elimination for a living organism having the electrical stimulation performed. Thus, for example, medical leads having electrode contacts have been implanted near the spinal column of the human body to provide pain relief for chronic intractable pain. The nerve tissue within the spinal column is stimulated electrically to reduce pain sensations at other parts of the body.
[0004] Depending on the location of the pain sensation, and the particularities of each different human body, the parameters of the stimulation signals applied near the electrically excitable tissue are adjusted to optimize pain reduction or elimination. For example, the area of excitation within the spinal column and the intensity of excitation can be varied by corresponding adjustment of the parameters of the stimulation signals.
[0005] During acute trial stimulation, in order to vary the area of excitation, an array of electrodes may be implanted near the nerve tissue within the spinal column or peripheral nerve. Then, each of those electrodes can be configured to have a polarity such that the desired area of the nerve tissue within the spinal column is electrically stimulated. In addition, parameters of the respective stimulation signal applied on each of those implanted electrodes can be varied for a corresponding variation in the area of excitation within the spinal column and in the intensity of excitation at the pain site. Once the array of electrodes is implanted, a clinician who is knowledgeable of the effects of electrical stimulation may vary the parameters of the respective stimulation signal applied on each of the implanted electrodes. The patient may rate the effectiveness in pain reduction for each variation in the parameters of the stimulation signals. Then during chronic stimulation if electrical stimulation of nerve tissue does result in sufficient pain reduction for the patient, then the medical lead is implanted for the long term with stimulation signals having parameters that lead to optimized pain reduction for the particular patient.
[0006] Although spinal stimulation has proven effective for pain relief, there are problems associated with it, especially stimulation in the high cervical region. The conduit providing passage of the spinal cord in the lumbar vertebra provides more room for the spinal cord when compared to the conduit for the spinal cord in the cervical vertebra. In the lumbar region the spinal cord has a smaller diameter and therefore there is more room within the conduit of the lumbar vertebrae. As the spinal cord traverses up through the lumbar region of the spine to the cervical region, more and more peripheral nerves come into the spinal cord at the dorsal roots and therefore there is less room within. This poses a significant problem when placing the stimulation leads since the space in which to place the leads is diminished substantially.
[0007] Presently there are two basic styles of implantable leads available. One style is the percutaneously inserted lead, which is introduced through a Touhy needle. The implanting physician places the lead stimulating electrodes in an appropriate location using fluoroscopic visualization and the procedure is done under a local anesthetic. An example of this type of lead is disclosed in U.S. Pat. No. 4,379,462 issued to Borkan. Percutaneously inserted leads can be used for pain reduction/elimination, however, there are problems associated with these leads.
[0008] Percutaneously inserted leads are difficult to anchor and have a tendency to become dislodged. Even if the initial placement is accurate, lead migration can occur which can adversely affect paresthesia. Further, if the percutaneously inserted lead migrates enough to touch an incoming dorsal root, this can be very painful for the patient. Additionally, the area in which the patient is experiencing pain can move. This is a significant problem since percutaneous leads provide only limited means to change the area of stimulation if the lead migrates or if the needs of the patient change. Such means include reconfiguring the electrodes providing stimulation or performing additional surgery to adjust the lead's position. This problem could be resolved by enlarging the electrodes to cover more spinal cord area, however, the electrodes must be made small enough to fit through a Touhy needle. Thus, the stimulation area for percutaneous leads remains consequently small and because of this even a slight movement of the lead, especially laterally, can adversely affect paresthesia.
[0009] Another possible problem with percutaneous leads is their thickness is relatively large in comparison with the thickness of the dura mater in the high cervical region. Presently percutaneous leads are typically 0.050 inches in diameter. Because of the limited space in the high cervical region, if the lead is inserted improperly or if the lead migrates when placed in the cervical region where the dura mater is very thin, the percutaneous lead could possibly cause compression of the dura mater into the spinal cord causing discomfort, excess pain, and even paralysis.
[0010] The second basic spinal cord stimulation lead type is commonly referred to as a surgical lead and is surgically implanted in a procedure referred to as a laminotomy. An example of this type of lead is the RESUME® lead manufactured by Medtronic, Inc. of Minneapolis, Minn., the assignee of the present invention. This lead has four in-line electrodes located on a flat rectangular paddle at the distal end of the lead and the lead is normally implanted outside of the dura mater. Since leads of this type are surgically implanted, the size of the electrodes may be made larger than those of the percutaneously implanted leads. Further, various electrode combinations can be selected so that the area of stimulation may be moved along the midline of the spinal cord. The surgical lead can provide a broader stimulation pattern more suitable for midline and bilateral pain problems than the percutaneously inserted lead. Moreover, since it is surgically implanted it can be sutured to try and prevent dislodgement and reduce lead migration.
[0011] Surgical leads are less affected by the problem of lead migration because of the shape and size of the paddle and sutures may stabilize the lead. However, presently the paddles are made of silicon rubber, which requires a thickness of approximately 0.070 inches. Current technology does not allow the manufacture of desirably thin silicone rubber paddles suitable for locations with small extradural spaces such as the high cervical region due to production tolerances, coverage specifications, and internal anti-stretch components, which must be added to make the lead less elastic. Further, thin rubber coverage on silicon rubber paddles over internal components; such as the electrodes, are known to lack durability. Since the physician is trying to fit a rectangular lead into a cylindrical passage there is the potential for compression of the dura mater on the spinal cord. Therefore, inserting this rectangular lead still risks compression of the dura mater into the spinal cord causing discomfort, excess pain, and even paralysis.
[0012] Therefore, what is clearly needed is a method and apparatus for lead implantation in the high cervical region, which provides both improved fixation to prevent migration and an improved paddle structure to prevent compression of the dura mater against the spinal cord. What is further needed is a method for producing a thin paddle lead having improved fixation for implantation in the high cervical region.
SUMMARY OF THE INVENTION
[0013] The present invention provides for an implantable medical lead for electrical stimulation. The medical lead is comprised of a paddle. The paddle having at least one electrode electrically connected to at least one conductor with the paddle supporting the electrodes. The paddle having a thickness of up to 0.030 inches for application to small areas within the human body.
[0014] In another embodiment of the present invention, the medical lead is comprised of a paddle. A first paddle portion having a cavity on the surface of the first paddle portion and a second paddle portion having at least one aperture. There is at least one electrode electrically connected to at least one conductor. The at least one electrode is placed in the cavity of the first paddle portion and is disposed between the fist paddle portion the second paddle portion. The at least one electrode is disposed in such a way that a portion of the electrodes is conductively exposed through the at least one aperture.
[0015] In another embodiment of the present invention, an implantable medical lead for electrical stimulation comprises curved paddle portions having a distal and proximal end. On the surface of a first paddle portion there is a cavity and on the proximal end there is an opening extending from the proximal end of the first paddle portion to the cavity. The cavity is able to receive a second paddle portion having a plurality of apertures. The cavity contains a plurality of electrodes disposed between the first paddle portion and the second paddle portion with a conductive surface of each electrode at least partially exposed through the plurality of apertures. A plurality of conductors extending through the opening from the proximal end to the cavity is electrically connected to at least one conductor.
[0016] Another aspect of the present invention provides for a method of treating a medical condition using electrical stimulation. A paddle having at least one electrode and a thickness up to 0.030 inches is implanted adjacent a spinal cord dura in the cervical region of the spinal column. The paddle is then positioned so that at least one electrode is positioned over an area of the spinal cord for which electrical stimulation is anticipated to provide at least partial relief from a medical condition. Electrical stimulation is then applied to at least one electrode to provide at least partial relief from the medical condition.
[0017] Another aspect of the present invention provides a method of manufacturing an implantable medical paddle lead for electrical stimulation. A first paddle portion is created having a cavity on one side and an inlet for receiving at least one conductor. A second paddle portion is created having at least one aperture. At least one electrode located in the cavity is connected to at least one conductor. The second paddle portion is then placed onto the first paddle portion so that at least one electrode is positioned between the first paddle portion and the second paddle portion and a portion of at least one electrode is conductively exposed through the at least one aperture. The second paddle portion is then connected to the first paddle portion so that the medical lead has a thickness up to 0.030 inches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a plan view of one embodiment of the surgical lead of the present invention;
[0019] FIG. 2 is an exploded top side view illustrating an improved surgical lead of the present invention;
[0020] FIG. 2 a is a top side view illustrating an improved surgical lead of the present invention;
[0021] FIG. 3 is a top side view of an embodiment of an improved connection between a conductor and an electrode;
[0022] FIG. 4 is a bottom side view of an embodiment of an improved connection between a conductor and an electrode;
[0023] FIG. 5 is a partial schematic view of the spinal cord of a patient with the implanted surgical lead paddle of FIG. 2 connected to a pulse generator;
[0024] FIG. 6 is a cross sectional view schematically illustrating the spinal column of a patient with the base member of FIG. 2 positioned on the dorsal side thereof;
DETAILED DESCRIPTION
[0025] To assist in an understanding of the invention, a preferred embodiment or embodiments will now be described in detail. Reference will be frequently taken to the figures, which are summarized above. Reference numerals will be used to indicate certain parts and locations in the figures. The same reference numerals will be used to indicate the same parts or locations throughout the figures unless otherwise indicated.
[0026] The present invention is not limited to only high cervical implantation or spinal stimulation leads, and may be employed in many of various types of therapeutic or diagnostic devices including spinal cord, peripheral nerve, deep brain, and deep brain stem stimulation leads. It is to be further understood, moreover, the present invention may be employed in many of various types of therapeutic or diagnostic leads and is not limited only to the high cervical leads. For purposes of illustration only, however, the present invention is below described in the context of high cervical implantation leads.
[0027] FIG. 1 is a plan view of one embodiment of a surgical lead of the present invention. Surgical lead 10 includes a pair of lead bodies 12 connected at their proximal end to a connector (not shown) of a type known in the art and at its distal end to a paddle 16 . Lead bodies 12 can be made of any physiologically inert material such as silicone rubber or polyethylene; however, lead bodies 12 are preferable made of polyurethane so as to be compatible with paddle 16 . Lead bodies 12 have lumens, which enclose at least one conductor 18 ( FIG. 3 ) and most preferably have a diameter of 0.050 inches. Conductor 18 interconnects at least one electrode 20 located within paddle 16
[0028] Referring to FIG. 2 , an exemplary embodiment of a paddle 16 for spinal cord, peripheral nerve, deep brain, and brain stem stimulation of the present invention is shown. Paddle 16 comprises a first paddle portion 22 and a second paddle portion 24 . First paddle portion 22 is further comprised of a cavity 26 and apertures 28 to accept at least one lead body 12 . Second paddle portion 24 has substantially the same shape as cavity 26 and is further comprised of openings 30 . Cavity 26 is able to receive electrodes 20 within, which are electrically connected to conductors 18 .
[0029] Paddle 16 is preferably comprised of molded transparent polyurethane and has a thickness no greater than 0.030 inches. Thickness is defined as the measurement taken from the bottom surface of paddle 16 to the top surface of paddle 16 . Due to the paddle's polyurethane construction paddle 16 is more durable than any other physiologically inert material such as silicone rubber or polyethylene. Further, paddle 16 has better coverage specifications such as reduced coverage requirements over encapsulated components due to the durability of polyurethene and does not require any extra internal components, such as anti-stretch devices, which can significantly add to the paddle's 16 thickness. It is contemplated that as technology in molding part tolerances and durability advances it may be possible to use other physiologically inert materials such as silicone rubber or polyethylene in the present invention and therefore their eventual use is contemplated.
[0030] As can be seen from FIG. 2 , paddle 16 is curved about axial line A. The curvature in paddle 16 is substantially similar to the natural curvature of the dura mater over the spinal cord. Further, the flexibility of polyurethane allows paddle 16 to easily form around the dura mater of the spinal cord depending on whether paddle 16 is implanted outside or inside of the dura mater. The size and curvature of paddle 16 eliminates any excess pressure on the dura mater or the spinal cord. First, the paddle's thickness allows for ease of implantation with reduced risk of spinal compression. Second, the base member's curvature eliminates excess spinal compression exhibited by inflexible rectangular paddle leads.
[0031] First paddle portion 22 of the present invention has a plurality of electrodes 20 arrayed along the length and across the width of first paddle portion 22 specifically within cavity 26 . Varieties of alternate arrays and numbers of electrodes are contemplated. Paddle 16 with the array of electrodes 20 transmits stimulation signals to surrounding human tissue. The implantable pulse generator ( FIG. 5 ) provides respective stimulation signals having specified signal parameters to selected electrodes 20 in the array. Thus, depending on the desired location and amount of tissue stimulation needed, the parameters of the stimulation signals can be controlled and directed to selected electrode contacts for targeted stimulation. Typically, for spinal cord stimulation, paddle 16 is placed outside the dura mater and stimulation occurs through the dura mater to the targeted tissue fibers within the spinal cord.
[0032] Referring to FIG. 2 a , as most preferred, paddle 16 has an array of eight electrodes 20 spaced axially along the length of first paddle portion 22 and laterally across the width. Electrode 20 sets upon first paddle portion 22 and protrudes slightly above the surface of plate body 24 in order to enhance tissue stimulation effectiveness. It is contemplated however, that electrode 20 can be recessed below the surface of second paddle portion 24 . The array of electrodes 20 spans distant stimulation points, for example, nerve fibers, and at the same time provides combinations that cover stimulation points that may be close together. Because the epidural space restricts the width of any implanted body, the array of the present invention must span distant stimulation points to maximize the number of nerve fibers that are stimulated through the array. A clinician may direct stimulation to various combinations of stimulation points covered by the array of the present invention by controlling the amount and frequency to each electrode 20 .
[0033] With reference again to FIG. 2 a , a preferred paddle of the present invention is shown.
[0034] In a preferred embodiment, first paddle portion 22 and second paddle portion 24 are fused together by injecting a volatile polyurethane adhesive inside of cavity 26 . After injecting the volatile polyurethane adhesive into cavity 26 , second paddle portion 24 is placed in cavity 26 with openings 30 accepting electrodes 20 within. The volatile polyurethane adhesive then begins to break down the polyurethane material of first paddle portion 22 and second paddle portion 24 . As the surfaces of cavity 26 and second paddle portion 24 begin to break down or liquefy, the polyurethane structures begin to run together and fuse. Thus, there is no longer two independent bodies, but only one paddle 16 .
[0035] Paddle 16 has a proximal end 90 and a distal end 92 . Proximal end 90 provides openings 28 to accept at least one of the lead bodies 12 carrying conductors 18 into first paddle portion 22 and coupling to electrodes 20 , which is discussed in more detail below. The distal end 92 is rounded and curved to prevent abrasion of human tissue for safer placement of the lead paddle at the desired stimulation area. The sides 94 of the paddle lead 16 are also rounded to prevent abrasion of tissue during implantation and while implanted. As discussed above, paddle 16 is curved laterally to match the curvature of the spinal cord dura mater. Curved paddle 16 enhances the likelihood of fiber stimulation by allowing electrodes 20 to be in close proximity to the targeted tissue fibers thus improving fiber recruitment. Moreover, as discussed above, a curved paddle 16 reduces the potential for compression of the spinal cord.
[0036] With reference to FIGS. 3 & 4 , a preferred embodiment of an improved connection between conductor 18 and electrode 20 is shown. Conductor 18 is contained in lead body 12 and generally extends from the connector (not shown) to paddle 16 . Conductor 18 can be manufactured from a wide range of materials that are electrically conductive such as nickel-titanium, platinum, gold, silver, palladium, other noble metals, and other alloys or metals suitable for use in the human body. However, in a preferred embodiment low impedance is desired. Therefore, the core of each conductor is manufactured from low impedance metal such as silver and the jacket is manufactured from a material with good mechanical strength properties such as MP35N. Conductor 18 preferably has a resistance of less than 10/ohms/cm (3 ohms/foot) and a tensile strength greater than 5N, however, other resistances and tensile strengths are contemplated. Further, conductor 18 preferably is electrically insulated with a flouro-polymer such as ethyletetraflouroethylene or polytetrafluoroethylene (PTFE) with a coating thickness of approximately 0.0005 inch. In a preferred embodiment conductor 18 comprises a plurality of wires configured as braided strand wire (BSW) and is capable of reliably conducting electrical current after having been subjected to numerous, repeated bending and torquing stresses. BSW is available in many configurations including seven wire BSW. Three wires, however, have been discovered to provide the best overall combination of maximum strength, minimum diameter, and maximum torque transfer between proximal and distal ends. Each wire preferably has a diameter of between about 0.002 and about 0.006 inches, and most preferably has a diameter of about 0.004 inches. The number of conductors may be increased to two, three, or more, dependent on need and generally to the number of electrical signals to be generated. The term “about” applies to all numeric values, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (i.e., having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure.
[0037] Electrodes 20 are preferably formed of a non-corrosive, highly conductive material.
[0038] Examples of such material include platinum and platinum alloys. In a preferred embodiment, electrodes 20 are formed of a platinum-iridium alloy. As can be seen in FIGS. 3 & 4 , electrode 20 has a hat-like structure with top surface 104 , an annular side surface 106 , a base 108 , and arches 110 & 112 which receive conduit 96 as discussed in more detail below. It is contemplated that electrode 20 can take on many structures including a flat structure as long as the structure is able to be held between first paddle portion and second paddle portion. Top surface 104 provides electrical contact with the tissue to be stimulated and preferably extends slightly beyond second paddle portion 24 as discussed above. Top surface 104 is also recessed to accommodate the dura mater of the spinal cord and thus further reduce any compression of the dura mater. Base 108 secures electrode 20 in-between first paddle portion 22 and second paddle portion 24 . When first paddle portion 22 and second paddle portion 24 are attached as discussed above, base 108 is placed between the two and thus prevents electrode 20 from being easily dislodged. In a preferred embodiment, and based on past studies to reduce the potential of lesions from smaller contact areas, the size of electrodes 20 is preferably approximately 3 square millimeters. However, electrode contacts of other suitable sizes are contemplated and within the scope of this invention.
[0039] In a preferred embodiment, conductor 18 is electrically attached to electrode 20 in a way, which provides improved strain relief. At the distal end of conductor 18 a portion of the conductor's coating is removed in preparation for attachment to electrode 20 . Conductor 18 is then inserted approximately halfway through conduit 96 of crimp sleeve 98 . By inserting conductor 18 approximately halfway through conduit 96 silver ion migration is mitigated. Previous connections connected the conductor directly to the electrode and if the conductor were comprised of silver the silver ions would pit or deteriorate the weld joint between the conductor and the electrode. This increased the chances of conductor separation and silver exposure to patient tissue. Next, crimp sleeve 98 is crimped to create a stable electrical attachment. Since, silver material is not ideal for forming a strong mechanical connection crimp sleeve 98 is also used provide a strong mechanical connection between conductor 18 and electrode 20 . Crimp sleeve 98 is then laser welded to electrode 20 at arches 110 & 112 located at proximal end 100 and distal end 102 respectively. Therefore, the improved connection between electrode 20 and conductor 18 provides an improved mechanical connection as well as a reduction in silver ion migration.
[0040] As shown in FIGS. 5 & 6 , paddle 16 is adapted to be implanted in a human patient along the dorsal side of the spinal column 74 . As best seen in FIG. 5 , typically the lead is implanted over the midline of the spinal cord. If more than one electrode 20 is used than each electrode can be independently selectable so that when paddle 16 is positioned as shown a variety of stimulation patterns may be selected by providing stimulation signals to two or more of electrodes 20 . An external pulse generator provides the stimulation signals or pulses during the screening procedure. After the initial electrode combination is selected, the lead is connected to an implanted pulse generator 76 by a lead extension 84 . Lead extension 84 has a connector 77 at its distal end, which connects to connector 14 and has a plug-in connector 79 at its proximal end, which connects to pulse generator 76 . Pulse generator 76 may be a fully implanted system such as the “ITREL I1” pulse generator available from Medtronic Inc.
[0041] In use, paddle 16 is designed to be implanted in the high cervical space where the space between the vertebrae and dura mater is very thin after the dura has been exposed by a partial laminectomy. As can be appreciated the base member's reduced thickness and curved structure not only improve electrical stimulation capabilities, but also reduce the risk of spinal cord compression by allowing paddle 16 to move with the spinal environment in contrast to the flat paddle being so tightly inserted that it causes compression during movement. Although the invention will be described primarily in connection with its implantation in the high cervical space along the dorsal column for use in stimulating the spinal cord as a method of treating pain, it should be noted that paddle 16 could be used for any spinal cord stimulation application such as stimulation to induce motor function or to inhibit spasticity. When used for such other applications the lead could be implanted laterally or on the ventral side of the spinal column. The lead is also suitable for use in applications other than spinal cord stimulation such as stimulation of peripheral nerves.
[0042] As discussed above, once the lead has been implanted a screening procedure is performed to determine if the position of the lead will adequately supply paresthesia to the desired location. During the screening process, various electrode combinations are tested until the right combination is achieved. By using the lead of the present invention various unilateral and/or bilateral stimulation combinations are possible.
[0043] After the screening process is completed and the lead is properly anchored in place the lead is disconnected from the external screening device and connected to the implanted pulse generator so that the entire system can be internalized. Once the stimulation system has been internalized the lead of the present invention provides the flexibility to make modifications to the area of paresthesia should the needs of the patient change or should there be any lead migration. This is done by changing the electrode combinations by external programming procedures well known in the art. Thus, the need for repositioning or removing the lead is greatly reduced.
[0044] Thus, embodiments of the Improved Surgical Lead Paddle for High Cervical
[0045] Implantation are disclosed. One skilled in the art will appreciate that the present invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow. | The present invention provides for an improved apparatus and method for electrical stimulation. A paddle having a thickness up to 0.030 inches is implanted adjacent the spinal cord dura mater to reduce the likelihood of paralysis due to stress on the spinal cord attributed to bulkier leads. The paddle is then positioned so that at least one of a plurality of electrodes is positioned over the area of the spinal cord requiring pain treatment; and then electric stimulation is applied to the electrodes to effect pain treatment. In another embodiment the paddle is curved about a vertical axis to substantially match the shape of a human spinal cord dura mater to help reduce lead migration | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
None
BACKGROUND OF INVENTION
The present invention relates to a device for animal waste disposal
It is desirable and frequently required by law that pet owners promptly remove pet dropping from public parks and sidewalks, as well as from private property, for health reasons, as well as the damage it does to grass and other vegetation.
As many pet owners do not wish to bend over and use papers or plastic bags to remove droppings by hand an array of devices have been developed.
However, many of these prior art device are deficient are deficient in one manner or another as will be discussed below. Virtually all prior art devices attempt to provide a more sanitary means of removing pet waste, that is to avoid contact. Some these prior art devices use one of more scoops o shovel shapes to capture the waste. Frequently, these prior art devices tend to either incompletely remove droppings, or if used to completely remove the dropping also require the removal of surrounding grass and soil, and are hence also injurious to landscaping.
Further, these devices also tend to collect animal waste residue, and hence require regular cleaning and additional maintenance.
If the tools are used move aggressively to remove all residues, more residues tend to stick to the tool. Further, the tool portion that contacts the waste can be difficult to clean.
Accordingly it is a first object of the invention to provide an improved means to remove animal droppings, and particular pet droppings wherein the user/handler need not stoop over.
It is yet another object of the invention to provide such an improved apparatus that can completely remove such animal waste, yet will not damage grass or ground cover.
It is still a further object of the invention to provide such a device having the above attributes, that while capable of completely removing such animal droppings of varying consistency, will not become soiled or clogged and will hence be easier to clean and maintain.
SUMMARY OF INVENTION
In the present invention, the first and other objects are achieved by providing a method of removing animal waste, the method comprising the steps of: providing a tool having a lateral lifting surface at one end, a plate disposed over said lifting surface for sweeping waste off the lifting surface when loaded thereon, wherein the lifting surface and plate are disposed at the end of a shaft, inserting the lifting surface under the waste to be removed, lifting the shaft upward to remove the waste from the ground, transporting the waste to a disposal container, translating the plate over the lifting surface to urge the waste there from whereby it falls in the disposal container.
In a second aspect of the invention other objects are achieved by providing a tool for animal waste removal, the tool comprising: a shaft having a top and a bottom, a handle at top of shaft, a lateral lifting surface disposed in a first common plane, said first common plan being substantially horizontal to and coupled to the bottom of said shaft, a plate disposed perpendicular and immediately above said plurality of tines, an actuator coupling said handle to said plate wherein the operation of said actuator via said handle urges said plate to move in said first common plane perpendicular to said lateral lifting surface.
In a third aspect of the invention other objects are achieved by providing a tool for animal waste removal, the tool comprising a shaft having a top and a bottom, a handle at top of shaft, a plurality of tines disposed in a first common plane, said first common plan being substantially horizontal to and coupled to the bottom of said shaft, a plate disposed perpendicular and immediately above said plurality of tines, an actuator coupling said handle to said plate wherein the operation of said actuator via said handle urges said plate to move in said first common plane perpendicular to said plurality of tines.
The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A-C are schematic elevations of the front, side and rear respectively of a first embodiment of the invention, while FIG. 1D is a plan view thereof.
FIG. 2A-C are schematic elevations of the front, side and rear respectively of a second embodiment of the invention, while FIG. 2D is a plan view thereof.
FIG. 3A-C are schematic elevations of the front, side and rear respectively of a third embodiment of the invention, while FIG. 3D is a plan view.
FIG. 3E is a plan view of the clip shown in FIG. 3A at section line E-E.
FIG. 4 is a perspective view of the interior of the actuator mechanism at the handle trigger end.
FIG. 5 is a perspective view of the interior of the actuator mechanism at the bottom of the shaft with the tines and moving plate.
FIG. 6A is a plan view of an alternative embodiment of the moving plate portion.
FIG. 6B is a plan view of another alternative embodiment of the moving plate portion.
FIG. 7A-C are schematic elevations of the front, side and rear respectively of a fourth embodiment of the invention, while FIG. 7D is a plan view thereof. FIG. 7E is an alternative embodiment of the portion shown in FIG. 7D .
FIGS. 8A and 8B illustrate an alternative embodiment of an actuator, in which FIG. 8A is a perspective view of the lower portion of the device from slightly above the side and FIG. 8B is a cut away perspective view of a portion of the interior mechanism of the actuator from slightly above and behind the lower portion of the device.
DETAILED DESCRIPTION
Referring to FIGS. 1 through 8 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved Animal Waste Disposal Tool, generally denominated 100 herein.
In accordance with a first embodiment of the present invention, FIG. 1 illustrates tool 100 having a shaft 110 having a top 110 a and a bottom 110 b , with a handle 120 generally disposed toward the top of shaft 110 . At the opposing or bottom end 110 b of shaft 110 a plurality of tines 130 are disposed in a first common plane 131 , said first common plane being substantially horizontal to and coupled to the bottom of said shaft. A plate 140 is disposed perpendicular and immediately above the plurality of tines 130
An actuator 150 coupling the handle 120 to plate 140 wherein the operation of said actuator 150 via said handle 120 urges said plate 140 to move in the common plane perpendicular to the plurality of tines 130 . Plate 140 is shown in alternative position in broken lines and labeled 140 ′ in the Figures.
It should be understood that is more preferable that each of the embodiments also comprises a spring biasing mechanism 180 , such as leaf spring(s) coils springs and torsion springs and the like, as shown in FIGS. 6A and 6B , as well as FIG. 7 . In particular, it is preferably a torsion spring when plate 140 rotates about or adjacent to shaft 110 in FIG. 5 . The spring 180 preferably supplies a constant and controlled minimum force to eject waste off the tines 130 .
As shown in FIG. 1 , the actuator mechanism 150 alternatives include a rotating bar connecting the plate to the handle, as well as a bar that slides in and out, each extending from the plate to the top of the shaft. The top of this bar is the handle. The bar can be connecting to the shaft at some intermediate position by a slide or pivot mechanism. The slide or pivot can include a biasing means. Actuator may include a cable actuator and/or a coupling to magnify the plate displacement with respect to the handle displacement. Alternative actuator mechanisms can be any found in the prior art search.
The tines 130 , being spaced apart with gaps is readily inserted under the waste matter without while slide through blades or grass and other vegetative matter. Accordingly, when the operator lifts the tool 100 upward, they pick up the waste but also do not damage the grass as it ready slips through the tines. Dispose.
Accordingly, it will now be appreciated that the device 100 improves sanitation and hygiene by complete removal without residue on the ground as animal waste can be removed without direct contact. Further, the user of the device need not stoop over to remove waste, nor carry, buy or find plastic bags is general purpose waste receptacle are in the general vicinity. The tine arrangement minimizes the potential for leaving waste residue on the tool, as the contact therewith is minimizes and not pressure is asserted to squeeze the waste onto the tool other than its own mass. Likewise, as the plate 140 slides across the tines 130 , and will readily remove the waste there from without leaving significant residue. Further, the tool 100 portions, which is the tines 130 and the plate 140 that contacts residue, are easy to clean.
In FIG. 1 the actuator 150 deploys another or secondary shaft 109 coupled at the bottom to the plate 140 and at the top to the handle 120 . The secondary shaft 109 and slides laterally with respect to the main supporting shaft 110 , remaining parallel thereto. Various combinations of spring 180 elements shown in other embodiments can be used to bias the plate 140 to either alternative position. Further, the secondary shaft 109 is optionally supported at the center as shown, but more preferably at both the top and bottom by slots or channel that extend from the main shaft 110 , so that it is restrained to move laterally.
In FIG. 2 the actuator 150 is another or secondary shaft 109 coupled at the bottom to the plate 140 and at the top to the handle 120 . The secondary shaft 109 pivots about the center of the main supporting shaft 110 , via a rotary coupling 160 , thus the movement of handle 120 forward, retracts plate 140 , while the backward movement propels it forward along with plate 140 to push waste matter off the tines 130 . Various combinations of spring 180 elements shown in other embodiments can be used to bias the plate 140 to either alternative position. The spring 180 elements can be at either the plate 140 end, the handle end 140 or a torsion spring in the rotary coupling 160 .
FIG. 3 illustrates a more preferred embodiment that further comprises rails 165 that extend above and parallel to the plurality of tines 130 . In various other embodiments the rails 165 also help stabilize the plate 140 , acting as plate guides. However, the primary function is to insure that waste cannot fall or slip sideways off the tines 140 was it is lifted off the ground. Preferably, the plate 140 has a lower portion with fingers that are inter-digitated to extend into the gaps between the tines 130 .
In the embodiment of FIG. 3 , the actuator mechanism 150 comprises a cable 151 that is responsive to squeezing the trigger 159 portion of handle 120 . The cable 151 terminates at the upper portion with a capping cylinder 152 , shown in more detail in FIG. 4 in a transparent perspective view. The capping cylinder 152 and the top portion of the cable 151 are inserted into the opposite end of the trigger 159 (distal from rotary coupling 159 a ) which has with a downward oriented bore hole 459 and a side slit 451 that extends laterally to reach the entire length of the bore hole 459 . The bore hole 459 . has an upper portion that is wide enough to retain the capping cylinder 152 . This upper portion is followed by a lower portion that is just wider than the cable, but narrower than the capping cylinder; so that when the cable is inserted in the slot and pulled downward (or the block pulled upward) the capping cylinder 152 will be retained in this bore hole 459 in the trigger 159 .
As shown in detail in FIG. 5 , the opposite end of the cable 151 at the base of shaft 110 , that is side 110 b , is connected in rotary engagement with a round gear 153 that is divided into two axially separated portions which are round gears 153 a and 153 b . The intervening axle 155 c is thus driven by the cable 151 via the grip handle trigger 159 . The trigger 159 mechanism has a rotary coupling 159 a at the end of the hand grip so that when it is squeezed and pulled backward into the handle the cable 151 is pulled upward. Then, at the opposite end of the actuator 150 , the cable 151 rotates the round gear 153 and urges the plate 140 backward, thus compressing the spring 180 .
The cable 151 is physically attached to the intervening axial 155 c . Further, at least one of the round step gears 153 a and 153 b has an off center external projection 502 on its outside that is intended to engage a similar projection 503 extending inward from the case 510 , and thus limit the range of rotary motion of the round gear 153 to the intended travel range of the cable 151 .
Each of the axially separated round step gears 153 a and 153 b simultaneously engage tracks of flat gear 155 . By flat gear we mean the arrangement of gear teeth in a linear co-planar arrangement. The portion of the flat gear 155 most distal from plate 140 has a vertical portion 555 for supporting a spring 180 . The end of spring 180 distal from plate 140 is connected toward the top of this vertical portion. The flat gear 155 fits and slides in the rectangular well in the base having a series of tracks 501 in the bottom that are in a triangular shape, making limited contact with the reverse side of the flat gear, opposite the teeth thereof, to minimize friction. However, these are merely the currently preferred embodiments of the flat gear and well, which need not have the shapes or contact areas shown, as other shapes such as circular, oval and trapezoidal are possible. The spring 180 that biases the plate 140 with respect to the bottom 110 b of the shaft 110 extends above and in the same direction as the track gear, being below the intervening axle 155 c , and thus in the gap between the round gears 153 a and 153 b.
The proximal end of the flat gear 155 is connected to the reverse side of plate 140 , which is the side facing shaft 110 . The proximal end of the spring 180 is connected or coupled to the base near the bottom 110 b of shaft 110 . The base thus has an aperture so that the flat gear can translated forward and backward as the actuator 150 is engaged.
Further, the handle 120 rotates for left and right handled operation, preferably includes a locking pin 111 in the shaft 110 , as the handle has an axial extension 112 that surrounds the upper portion 110 a of shaft 110 , a common lateral locking pin 111 extends through a pair of common lateral holes to prevent the handle 120 from sliding on shaft 110 . The locking pin 111 in spring 402 biased detent mechanism that prevent the handle extension portion 112 from rotating with respect to shaft 110 until it is depressed. Locking pin 111 also enable handle 120 to rotate 180 degrees for left and right handled operation. A clip 113 on shaft 110 for holding the shaft on an associated pan with handle. Preferably, but not exclusively, plate 140 moves in the direction of the tines 140 principle axis 145 .
As shown in FIG. 5 , spring 180 is normally biased to urge the plate 140 toward the end of the tines 130 . Then, when the trigger 159 is squeezed and pulled back into the handle, the upward movement of the cable 151 will rotate the round gear 153 thus, causing the plate 140 to move inward from the end of the tines 130 back toward the case 510 . It should be appreciated that another alternative embodiment is attaching a spring to the farthest right side of housing of the case 510 to the vertical extension 555 which will bias the plate 140 and flat gear 155 back into the case 510 . Then, when the trigger 159 is squeezed and pulled back into the handle, the upward movement of the cable 151 will rotate the round gear 153 thus, causing the plate 140 to move outward to the end of the tines 130 .
Alternatively, as shown in embodiment of FIGS. 7D and 7E , the tines 130 are optionally linear or curved respectively, curves tines being preferable when the plate 140 rotates rather than translates in a complete lateral fashion.
In FIG. 6A , guide rails 165 are shown as also having rearward extending appendages 165 b to plate 140 , spaced above tines 130 attached to side 110 b of the shaft 110 . More preferably, a spring 180 is coiled around each guide rail appendage 165 b , which are behind plate 140 to avoid fouling. Further, the ends 165 a of guide rails 165 b extend through mating holes in the base about shaft side 110 b , and thus stabilize plate 140 . FIG. 6B illustrates one alternative embodiment for using a leaf spring 180 , as opposed to ordinary coil springs 180 and 180 ′ in FIG. 6A . While leaf spring 180 is oriented with the wide side vertical, it is also possible to deploy leaf springs of other shapes and orientation. Note that the guide rails 165 are attached to the front of plate 140 , moving forward therewith. This alternative embodiment can be used with any of the actuator embodiments described herein.
FIG. 7A-C are schematic elevations of the front, side and rear of a fourth embodiment of the invention, and secondary shaft 109 attached to edge of the plate 140 via a vertical rotary coupling 161 . Thus the upper portion of the secondary shaft 109 preferably includes a horizontally extending handle 720 that together with the handle 120 essentially form a trigger mechanism for actuator 150 . The plate 140 translates in the plane of the tines by rotating across the tines 130 .
In FIG. 7D , which is an alternative embodiment of the portion shown in FIG. 7C , the tines 130 are curved following the curving track of plate 140 . It should be apparent that this configuration of curved tines 130 may also be preferable to use with the actuator embodiment shown in FIG. 2 . Further, in any of the embodiment the tines 130 and guide rails 165 may have cross sectional shape is optionally round, square, inverted triangles (point up), or flattened or oval. Further, plurality of tines 140 can be replaced with a large flat rectangle lifting plate having the same dimensions, although this would be less desirable for removing animal excrement from grass surface. The plate 140 can move from the handle side of the tine array 130 to the tip thereof in response to the actuator 150 , or in the opposite direction so that the rest position of the plate is either at the edge of the tines or at the connection between the tines and the shaft.
FIGS. 8A and 8B illustrate an alternative embodiment for a lower portion of the actuator wherein the portion thereof coupled to the flat plate 140 deploys pairs of hinged arms 801 a and 801 b that unfold to translate the plate 140 across the tines 130 . The pairs of hinged arms 801 a and 801 b on one side of tine array 130 are connected by cross members 813 and 814 to the pairs of hinged arms 801 ′ a and 801 ′ b on the opposite side of the tine array. Arms 801 a and 801 b are connected in rotary engagement by a pin 801 a , as are hinged arms 801 a ′ and 801 b′
In FIG. 8A , the opposite end of each hinge arm 801 b is connected the near side of plate 140 in rotary engagement via another pin 805 a , with arm 801 a ′ likewise connected to the opposite side of plate 140 via another rotary pin connection.
The opposite side of hinge arm 801 b and 801 b ′ are connected to the near and far sides of the wide base 835 in rotary engagement via pins 805 b . The base 835 is orthogonal to shaft 110 and has about the same width as plate 140 .
The plate 140 has two guide rail sleeves 803 located at opposite ends which enable the plate to slide along the guide rails 165 . Pairs of torsion spring 802 are coupled to the interior walls of hinge arms 801 a and 801 b to bias the rotation there between at pin 801 c and 801 c ′, normally urging the plate 140 toward the end of the tines 130 .
As shown in detail in FIG. 8B , a pulley 812 is connected in rotary engagement at the base of shaft 110 . The opposite end of the cable 151 that is attached to the trigger 159 is attached to the axle 810 of pulley 812 . Attached to the outer wall of axle 810 is a cable guide 809 that will prevent the cable 151 from slipping off. A second cable 804 is wrapped around protruding post 806 for attachment to the plate 140 . The opposite end of the cable 804 is attached to a second axle 807 , which has co-axial cable guide 808 a and 808 b to prevent the cable 804 from slipping off laterally. The intervening axle 810 is thus driven by the cable 151 via the grip handle trigger 159 . The trigger 159 mechanism has a rotary coupling 159 a at the end of the hand grip so that when it is squeezed and pulled backward into the handle the cable 151 is pulled upward. Then, at the opposite end of the actuator 800 , the cable 151 rotates the pulley 812 and urges the plate 140 backwards, via the second cable 804 that is attached to the plate 140 , thus compressing the spring 802 .
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be within the spirit and scope of the invention as defined by the appended claims. For example, it should be appreciated that alternative embodiments also include combination of mechanisms shown in one embodiment with those shown in another. | A tool for retrieving animal waste is effective in complete removal as it deploys at its end a row of tines that are inserted beneath the solid waste so that is can be lifted from the ground as the first step for proper disposal. The waste is then removed from the tines by a plate that pushes it off into a waste receptacle. | 4 |
This application claims the benefit of and claims priority to Application Ser. No. 60/743,140 filed on Jan. 18, 2006 and is incorporated herein by reference.
BACKGROUND
The present invention relates to nozzles for a shower pipe to spray wash liquid onto a pulp mat.
Pulp is typically processed in mills by soaking or mixing wood pieces in tanks with chemicals that convert the wood pieces into pulp, and then bleaching pulp. The processing typically involves repeated stages of mixing the pulp with liquid and drawing the liquid out of the pulp by allowing the pulp to form mats on cylindrical vacuum drums. The pulp mats are washed by spraying wash liquid onto the mats. The wash liquid cleans chemicals out of the pulp mat. The wash liquid is sprayed from nozzles attached to liquid pipes spanning the width of the vacuum drums. There is a long felt need for liquid pipes and nozzle assemblies that uniformly spray wash liquid onto the mat and are inexpensive to manufacture and operate.
SUMMARY
A shower pipe and nozzle assembly for spraying a wash liquid on a pulp including: apertures in the pipe extending a length of the pipe spanning a width of the pulp mat, are laterally aligned along two or more rows such that adjacent apertures are in different rows, and the nozzle assembly includes a nozzle, a mounting block and a lip wherein the nozzle includes a hollow stem that attaches to the aperture and secures the nozzle assembly to the pipe, the block has a face that conforms to the pipe surface surrounding the aperture, an opposite face supporting the lip and an opening for the nozzle stem which is offset from a center of the block, and the lip includes a curved fan for turning wash liquid from the nozzle towards the pulp mat, a mounting surface abutting the opposite face of the block and a corner fitting over an edge of the block. The wash liquid flows through the pipe, the hollow stem of the nozzle and out of the nozzle as a stream that is generally tangential to the lip. The fan of the lip gradually turns the water towards the pulp mat and spreads the stream such that the water is sprayed uniformly on the mat. The multiple rows of apertures and nozzles project wash liquid towards the mat at different directions.
A nozzle assembly for spraying a wash liquid onto a pulp mat, the assembly comprising: a fastener-nozzle having an internal conduit for the wash liquid, an external fastener structure for attaching to an aperture in a wash liquid pipe and an outlet to the internal conduit for discharging the wash liquid, and a curved lip having a curved surface mounted to the pipe by the fastener-nozzle extending from the outlet to the internal conduct, the curved surface having an expanding width to convert a stream of wash liquid from the outlet to a sheet of wash liquid directed to the mat. A mounting block may be included in the assembly between the pipe and lip, wherein the block has an offset opening to receive the fastener-nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a shower pipe and nozzle assembly, and a section of a pulp mat on a cylindrical dryer.
FIG. 2 is a cross-sectional view of the shower pipe and nozzle assembly, showing just one nozzle assembly.
FIG. 3 is a top view of the lip of the nozzle assembly.
FIG. 4 is an enlarged cross-sectional view of the nozzle assembly showing the hollow nozzle stem attached to an aperture in the pipe, a mounting block for the nozzle assembly, and a portion of the lip of the nozzle assembly.
FIG. 5 is a cross-sectional view of the shower pipe and nozzle assembly taken along line 5 - 5 in FIG. 1 and showing a side view of a portion of the pulp mat and cylindrical dryer.
FIG. 6 is an exploded isometric view of the nozzle assembly and a portion of the pipe.
DETAILED DESCRIPTION
FIG. 1 shows a shower pipe 10 that sprays a wash liquid 12 onto a pulp mat 14 . The mat (shown by dotted lines) forms on a rotating cylindrical vacuum drum 16 . The liquid wash is sprayed evenly and uniformly on the mat in one, two or more wash liquid sheets. The shower pipe 10 is positioned near the surface of the mat 14 and drum 16 . The shower pipe may be an extended cylinder spanning the width (W) of the vacuum drum. The pipe may be circular in cross-section, but may be rectangular, curvilinear or have some other cross-sectional shape. The pipe is preferably hollow and has an interior closed conduit 26 through which flows the wash liquid. A source 18 of liquid wash is connected to one or both ends of the pipe.
Wash liquid nozzle assemblies 20 are arranged along the length of the pipe 10 . The nozzle assemblies may be aligned in one, two or more rows extending laterally along the pipe. In the embodiment shown in FIG. 1 , the nozzle assemblies are arranged along a first row 22 and a second row 24 . The rows may be angularly offset by an angle (A in FIG. 5 ) that may be in a range of 3 degrees to 20 degrees. The nozzle assemblies 20 may be arranged to alternate between the rows along the length of the pipe. The nozzle assemblies may be equally spaced along the pipe and the spacing may be determined to provide a relatively uniform spray of wash liquid on the pulp mat 14 . The dotted lines in FIG. 1 between the nozzle assemblies and the mat 14 indicate a uniform flow of two sheets of wash liquid being sprayed onto the mat. Preferably, the sprays from two adjacent nozzle assemblies on the same row (and separated by at least one other nozzle assembly on another row) do not overlap.
FIG. 2 is a cross-sectional view of the pipe 10 and a single nozzle assembly 20 . The interior surface of the pipe defines a wash liquid passage 26 . Along each row in the pipe are a series of equally spaced apertures 28 that receive a nozzle-fastener 30 of the nozzle assembly. The apertures 28 may be threaded to receive a threaded stem portion of the nozzle fastener. The apertures 28 may be tapered to ease insertion of the fastener. Wash liquid flows through a hollow passage 32 of the stem of the nozzle-fastener. This hollow passage has an inlet open to the liquid passage 26 and an outlet 34 for projecting wash liquid relatively tangentially to a lip 36 of the nozzle assembly. The nozzle-fastener also secures the nozzle assembly to the pipe, and extends through openings in the lip 36 and in the mounting block 46 ( FIG. 4 ).
As show in FIG. 3 , the lip 36 may have a curved surface 38 that has a radially inward section (near the pipe) that is relatively tangent to the circumference of the pipe and perpendicular to the stream of wash liquid flowing from the nozzle. The lip includes a radially outward portion that both curves into the wash liquid stream and expands laterally. The lip may be a generally thin metal or plastic plate having a curved surface 38 , a mounting section 48 and a corner 50 . The mounting section 48 is a flat planar section that abuts an outside face 51 of the mounting block 46 . The corner 50 is a right angled lip that fits over an outside edge 52 of the mounting block. In top view ( FIG. 3 ), the curved surface of the lip is relatively narrow near the nozzle outlet 34 and expands into a fan-like shape. The curved surface 38 of the lip causes the water stream to spread out into a fan shaped liquid spray that flows to the pulp mat.
FIG. 4 is an enlarged view of a nozzle assembly 20 attached to the pipe 10 . The nozzle-fastener 30 includes a threaded stem 42 that screws into a threaded aperture 28 in the pipe. The head 44 of the nozzle-fastener may be a hexed bolt head. In one embodiment, the nozzle-fastener is a bolt having a hollow passage 32 that provides a wash fluid conduit from the liquid passage 26 in the pipe to the nozzle outlet 34 . The nozzle-fastener secures the nozzle assembly to the pipe.
The nozzle assembly may also include a mounting block 46 that is generally rectangular and has a first side that conforms to and abuts an outer surface of the pipe. The mounting block includes a second side, opposite to the first side, that is generally planar and provides a support surface for a planar mounting section 48 of the lip. An opening 54 through the mounting block receives the stem of the nozzle-fastener, but may not be threaded. The opening 54 in the block may be offset (see difference of lines D and C) from a center of the block. The offset allows the outlet 34 of the fastener-nozzle to be in close proximity to the radially inward portion of the curved surface 38 of the lip 36 . The second side of the mounting block abuts against the planar mounting section 48 of the lip 36 , when the nozzle-fastener secures the assembly 20 to the pipe. The corner 50 of the lip is a narrow strip that forms a 90-degree corner with respect to the mounting section 48 of the lip. When fitted to the mounting block, the corner 50 folds over an edge 52 of the mounting block and thereby assists preventing the lip from rotating about the mounting block and nozzle-fastener.
FIG. 5 shows wash liquid jetting from the outlet 34 of the passage 32 through the nozzle-fastener and flowing onto the curved surface 38 of the lip 36 . The lip spreads the water stream and turns the water stream towards a tangent of the pulp mat 14 and cylindrical drum 16 . Preferably, the spray of wash liquid from each row 22 , 24 of nozzle assemblies is a generally uniform across the width of the mat. The angle (E, F) between the wash spray and mat depends on the row of the nozzle assembly and the amount of curvature in the lip. In the embodiment shown in FIG. 5 , two sheets of wash liquid 55 , 56 flow onto the pulp mat, where each sheet is from one of the two rows of nozzle assemblies.
FIG. 6 is an exploded view of the pipe 10 and a nozzle assembly 20 . A nozzle-fastener 30 is inserted through an opening in the mounting section 48 of the lip 36 and an opening 54 in the mounting block 46 . The stem 42 of the nozzle-fastener screws into a threaded aperture 28 of the pipe to secure the mounting block to the pipe and the lip to the mounting block. The corner 50 of the lip fits around an edge of the mounting block to prevent rotation of the lip.
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 nozzle assembly for spraying a wash liquid towards a pulp mat, the assembly including an integral fastener-nozzle having a conduit for the wash liquid, an outlet to the conduit for discharging the wash liquid and an attachment to secure the fastener-nozzle to an aperture in a wash liquid pipe, and a wash liquid direction device extending outwardly from the pipe and adapted to direct the wash liquid from the outlet towards the pulp mat. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a control program, a control method, and a game device.
Background Art
[0002] A domination game in which a plurality of players respectively occupies a plurality of territories included in a game field and deprives a territory of other players is known. In such a domination game, a game in which a player correlates the owned point (which may be virtual currency and the like) or the owned character, with a territory, and the player competes with another player for the territory, in accordance with the amount of points or the strength of the character correlated with the territory may be performed.
[0003] For example, JP-A-2014-73164 discloses a game program for realizing a domination game in which a competition may be executed between players who respectively own territories, and the territory owned by the player losing in the competition may be ceded to the player winning in the competition.
SUMMARY OF THE INVENTION
[0004] However, in the domination game of the related art, it may be determined whether or not the territory of a player can be acquired, based on the amount of owned points, the strength of the owned character of the player, and the like. Thus, it may not be possible for a player to progress the game by using a strategy. In addition, a player can easily predict a game result based on the amount of points owned by the player, the strength of the owned character of the player, and the like, which may reduce the will of the player to continuously play the game.
[0005] To solve the above problem, according to an exemplary embodiment, a control program, a control method, and a game device which can realize a game which requires a strategy of a player, which can thereby improve the player's interest in the game may be provided.
[0006] According to an exemplary embodiment, there may be provided a control program of a game device which includes a storage unit and progresses a game by using a game field including a plurality of game regions. The control program may cause the game device to execute: storing, in the storage unit, points which are respectively associated with a plurality of players; correlating at least a portion of the points associated with a first player with a game region designated by the first player among the plurality of game regions in accordance with a request of the first player, and designating these correlated points as region points of the first player; setting the game region correlated with the region points of the first player to be a corresponding region of the first player in a case where the region points of the first player are greater than the region points of a player different from the first player in the game region correlated with the region points of the first player; in a case where game regions (between the corresponding region of the first player, which is set, and another corresponding region of the first player, which has been previously set) are disposed in predetermined arrangement, and all of the game regions disposed in the predetermined arrangement are corresponding regions of a player different from the first player, extracting region points of the first player correlated with the game regions disposed in the predetermined arrangement, and region points of the player who has the game regions as the corresponding regions; and correlating the extracted region points of the player, as the region points of the first player, with the game regions disposed in the predetermined arrangement, and setting the game regions disposed in the predetermined arrangement, to be corresponding regions of the first player in a case where the region points of the first player are larger than the region points of the player, which have been correlated with the game regions, in the game regions disposed in the predetermined arrangement.
[0007] In the control program according to an exemplary embodiment, the game device may cause the extracted region points of the first player to be correlated, as the region points of the player who has the game regions as the corresponding regions, with the game regions disposed in the predetermined arrangement.
[0008] In the control program according to an exemplary embodiment, in a case where the first player designates a first specific region from the plurality of game regions when the region points are correlated in accordance with a request of the first player, a predetermined point value and the points correlated as the region points may be consumed from the points stored in the storage unit.
[0009] In the control program according to an exemplary embodiment, the game field may include a restricted region of which designation by a player may not be possible, and the restricted region may be changed to a game region depending on the number of times region points are correlated according to the request of the first player.
[0010] In the control program according to an exemplary embodiment, i the game device may be caused to execute a process which may include specifying color information associated with the first player in the corresponding region of the first player, changing brightness, chroma, or hue of the specified color information, based on both or any one of the region point of the first player and the region point of another player, which may be correlated with the corresponding region of the first player, and displaying the corresponding region of the first player with the changed color information.
[0011] According to another exemplary embodiment, there may be provided a control program of a game device which may include a storage unit and may progress a game by using a game field including a plurality of game regions. The control program may cause the game device to execute: storing points which may be respectively associated with a plurality of players, in the storage unit; correlating at least a portion of the points associated with a first player, as region points of the first player, with a game region designated by the first player among the plurality of game regions in accordance with a request of the first player; setting the game region correlated with the region points of the first player to be a corresponding region of a first group, in a case where a summation value of region points of players included in the first group to which the first player belongs is larger than a summation value of region points of players included in a group different from the first group, in the game region correlated with the region point of the first player; in a case where game regions between the corresponding region of the first group which may be set, and another corresponding region of the first group, which has been previously set are disposed in a predetermined arrangement, and all of the game regions disposed in the predetermined arrangement may be corresponding regions of a second group different from the first group, extracting region points of the first group correlated with the game regions disposed in the predetermined arrangement, and region points of the second group who has the game regions as the corresponding regions; and correlating the extracted region points of the group, as the region points of the first group, with the game regions disposed in the predetermined arrangement, and setting the game regions disposed in the predetermined arrangement, to be corresponding regions of the first group in a case where the region points of the first group are larger than the region points of the second group, in the game regions disposed in the predetermined arrangement.
[0012] In the control program according to another exemplary embodiment, the game device may be caused to execute a process which may include calculating a summation value of region points correlated by each player, for each of the players included in the first group, and storing a player reward depending on the calculated summation value, in the storage unit in association with each player; and storing a group reward depending on a summation value of region points of the first group, which may be correlated with corresponding regions of the first group, in the storage unit in association with each of the players included in the first group.
[0013] According to still another exemplary embodiment, there may be provided a control method of a game device which may include a storage unit and may progress a game by using a game field including a plurality of game regions. The control method may include storing points which may be respectively associated with a plurality of players, in the storage unit; correlating at least a portion of the points associated with a first player, as region points of the first player, with a game region designated by the first player among the plurality of game regions in accordance with a request of the first player; setting the game region correlated with the region points of the first player to be a corresponding region of the first player in a case where the region points of the first player are larger than the region points of a player different from the first player in the game region correlated with the region points of the first player; in a case where game regions between the corresponding region of the first player which may be set, and another corresponding region of the first player, which has been previously set are disposed in predetermined arrangement, and all of the game regions disposed in the predetermined arrangement may be corresponding regions of a player different from the first player, extracting region points of the first player correlated with the game regions disposed in the predetermined arrangement, and region points of the player who has the game regions as the corresponding regions; and correlating the extracted region points of the player, as the region points of the first player, with the game regions disposed in the predetermined arrangement, and setting the game regions disposed in the predetermined arrangement, to be corresponding regions of the first player in a case where the region points of the first player may be larger than the region points of the player, which have been correlated with the game regions, in the game regions disposed in the predetermined arrangement.
[0014] According to still another exemplary embodiment, there may be provided a game device which may progress a game by using a game field including a plurality of game regions. The game device may include a storage unit that stores points which may be respectively associated with a plurality of players; a correlation unit that correlates (i.e. links/associates/stores) at least a portion of the points associated with a first player, as region points of the first player, with a game region designated by the first player among the plurality of game regions in accordance with a request of the first player; and a setting unit that sets the game region correlated with the region points of the first player, to be a corresponding region of the first player in a case where the region point of the first player is larger than a region point of a player different from the first player in the game region correlated with the region point of the first player. In a case where game regions between the corresponding region of the first player which may be set, and another corresponding region of the first player, which has been previously set may be disposed in predetermined arrangement, and all of the game region disposed in the predetermined arrangement may be corresponding regions of a player different from the first player, the correlation unit may extract region points of the first player correlated with the game regions disposed in the predetermined arrangement, and region points of the player who has the game regions as the corresponding regions, and may correlate the extracted region points of the player, as the region points of the first player, with the game regions disposed in the predetermined arrangement. The setting unit may set the game regions disposed in the predetermined arrangement, to be corresponding regions of the first player in a case where the region points of the first player may be larger than the region points of the player, which have been correlated with the game regions, in the game regions disposed in the predetermined arrangement.
[0015] According to the control program, the control method, and the game device of the invention, it may be possible to realize a game requiring the player to exercise a strategy, which may thus improve the player's interest in the game.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1A and 1B are diagrams illustrating an example of a game provided by a game device.
[0017] FIG. 2 is a diagram illustrating another example of the game provided by the game device.
[0018] FIG. 3 is a diagram illustrating an example of a schematic configuration of a game system.
[0019] FIG. 4 is a diagram illustrating an example of a schematic configuration of a portable terminal.
[0020] FIGS. 5A and 5B are diagrams illustrating an example of a game screen displayed by the portable terminal.
[0021] FIGS. 6A and 6B are diagrams illustrating another example of the game screen displayed by the portable terminal.
[0022] FIGS. 7A and 7B are diagrams illustrating an example of a game screen displayed by the portable terminal.
[0023] FIGS. 8A and 8B are diagrams illustrating an example of a game screen displayed by the portable terminal.
[0024] FIGS. 9A and 9B are diagrams illustrating still another example of the game screen displayed by the portable terminal.
[0025] FIG. 10 is a schematic diagram illustrating an example of setting a corresponding region.
[0026] FIG. 11 is a schematic diagram illustrating the example of setting the corresponding region.
[0027] FIG. 12 is a schematic diagram illustrating the example of setting the corresponding region.
[0028] FIG. 13 is a schematic diagram illustrating an example of region-point changing processing.
[0029] FIG. 14 is a schematic diagram illustrating the example of the region-point changing processing.
[0030] FIG. 15 is a schematic diagram illustrating the example of the region-point changing processing.
[0031] FIG. 16 is a schematic diagram illustrating the example of the region-point changing processing.
[0032] FIG. 17 is a diagram illustrating an example of a schematic configuration of a server.
[0033] FIGS. 18A and 18B are diagrams illustrating an example of data structures of various tables.
[0034] FIGS. 19A and 19B are diagrams illustrating an example of data structures of various tables.
[0035] FIG. 20 is a diagram illustrating an example of an operation sequence of the game system.
[0036] FIG. 21 is a diagram illustrating an example of an operation flow of game progress processing.
[0037] FIGS. 22A and 22B are schematic diagrams illustrating an example of a game field.
[0038] FIG. 23 is a diagram illustrating another example of the operation sequence of the game system.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Hereinafter, various exemplary embodiments will be described with reference to the drawings. It may not beed that the technical range of the present invention may not be limited to the exemplary embodiments described herein, and the exemplary embodiments described in claims and equivalents thereof may be included.
[0040] Outline of Game
[0041] FIGS. 1A to 2 may be diagrams illustrating an example of a game that may be provided by a game device. An example of a game provided by a game device according to an embodiment will be described below with reference to FIGS. 1A to 2 .
[0042] In an exemplary embodiment, a player may progress a game in which a game region may be correlated with a player, by operating the game device that displays a game field including a plurality of game regions on a display screen, so as to designate the game region. The game region may be a predetermined closed region which may be displayed on the display screen and may be designated by an input of a player. A game object, such as a panel, a card, or a character, may be used instead of the game region. The game field may be a game space which may be displayed on the display screen and may be used for disposing a plurality of game regions. As an example, a domination game in which a plurality of players (player A, player B, and player C) participate, which may be a game progressed by the game device, will be described below.
[0043] As illustrated in FIGS. 1A to 2 , a game field F including a plurality of game regions R may be displayed on the display screen of the game device, and the game device may cause the domination game using the displayed game field F to progress. Each of the plurality of players participating in the domination game may have a number of owned points. The owned points correspond to numerical information of virtual currency, game execution points, and the like. In a case where a predetermined condition may be satisfied in the game, the owned points may be stored by the game device, associated with the player. For example, in a case where it is determined that the game may be started, in a case where it is determined that a predetermined period elapses from the start of the game, or in a case where a progress state of the game coincides with a specific situation, the owned points may be stored in association with the player. The case where a progress state of the game coincides with a specific situation refers to a case where a specific game region R may be set as a corresponding region of a player, which will be described later, a case where the number of corresponding regions of a player reaches a predetermined value, a case where the number of times of a game region R being designated by a player reaches a predetermined value, or the like. In this case, region points of a player and/or points of a value corresponding to the region points of another player in the corresponding region may be given to the player as owned points.
[0044] Each of the plurality of players participating in the domination game may designate a game region R included in the displayed game field F, in a predetermined order. The predetermined order may be referred to as an input operation order below. A player who performs an input operation in the input operation order may be an example of a first player. The game device may receive a request of a player, which may include information indicating a game region R which has been designated by the player. The game device may correlate a portion of the owned points associated with the player, with the game region R designated by the player, in accordance with the received request of the player. The owned points of one or each of the plurality of players who respectively designate game regions R may be associated with the corresponding game region R. The owned points correlated with the game region R may be referred to as region points below.
[0045] In a case where the region points may be correlated with the game region R by the request of the player, the game device may determine whether or not the region points of the player, which may be correlated with the game region R may be larger than the region points of another player, which may be correlated with the game region R. In a case where the game device determines that the region points of the player, which may be correlated with the game region Rare larger than the region points of another player, which may be correlated with the game region R, the game device may set the game region R to be a corresponding region of the player. In this manner, the game device sets each of the plurality of game regions R to be a corresponding region of the player which may be correlated with the largest value of region points among region points correlated with the game region R.
[0046] In the example of the game field F illustrated in FIG. 1A , 30 points, 20 points, and 10 points may be correlated with a game region Ra 1 , as the region points of a first player, player A, a second player, player B, and a third player, player C, respectively. 20 points, 30 points, and 10 points may be correlated with a game region Rb 1 , as the region points of player A, player B, and player C, respectively. 20 points, 10 points, and 30 points may be correlated with a game region Rc 1 , as the region points of player A, player B, and player C, respectively.
[0047] Players correlated with the region point having the largest value among the region points which may be respectively correlated with the game region Ra 1 , the game region Rb 1 , and the game region Rc 1 may be player A, player B, and player C. Thus, the game region Ra 1 may be set as the corresponding region of player A, the game region Rb 1 may be set as the corresponding region of player B, and the game region Rc 1 may be set as the corresponding region of player C.
[0048] FIG. 1B illustrates a case where 100 points of the owned points of player A may be correlated with a game region Ra 2 , as region points. The game region Ra 2 has not been designated by player A, player B, and player C before. Thus, before player A correlates the region points of 100 points with the game region Ra 2 , 0 points have been correlated with the game region Ra 2 , as the region points of player A, player B, and player C, respectively. However, at this time, the region point of 100 points may be correlated with game region Ra 2 by player A. Thus, the game region Ra 2 may be set as the corresponding region of player A, who correlates the region point having the largest value with the game region Ra 2 .
[0049] An example of region points changing processing executed by the game device in a case where the game region Ra 2 may be set as the corresponding region of player A will be described below.
[0050] Firstly, the game device may specify the corresponding region Ra 1 of player A, which has been previously set and may be different from the corresponding region Ra 2 of player A, which may be set this time. Then, the game device may determine whether or not one or a plurality of game regions R (in FIG. 1B , Rb 1 and Rc 1 ) between the corresponding region Ra 2 of player A which may be set, and the specified corresponding region Ra 1 of player A may be disposed in a predetermined arrangement. The predetermined arrangement may be an arrangement of game regions R on a predetermined line which has end points in the corresponding region Ra 2 of player A, which may be set this time, and in the corresponding region Ra 1 of player A, which has been previously set. The predetermined line may have a shape of a straight line, a polygonal line, a curved line, or the like.
[0051] In a case where the game device determines that the game regions Rb 1 and Rc 1 are disposed in the predetermined arrangement, the game device may determine whether or not all of the determined game regions Rb 1 and Rc 1 maybe corresponding regions of another player who may be different from player A. Then, in a case where the game device determines that all of the game regions Rb 1 and Rc 1 are the corresponding regions of the other player, the game device may extract region points of player A correlated with the game regions Rb 1 and Rc 1 , and region points of the other player who has the game regions Rb 1 and Rc 1 as the corresponding regions.
[0052] In the example of the game field F illustrated in FIG. 2 , the region points (20 points) of player A, which may be correlated with the game region Rb 1 , and the region points (30 points) of player B who has the game region Rb 1 as the corresponding region may be extracted. The region points (20 points) of player A, which may be correlated with the game region Rc 1 , and the region points (30 points) of player C who has the game region Rc 1 as the corresponding region may be extracted.
[0053] Regarding the game region Rb 1 , the game device may replaces the extracted region points of player A with the extracted region points of player B, and correlates the replaced region points with the game region Rb 1 . That is, regarding the game region Rb 1 , the game device correlates the extracted region points (30 points) of player B, with the game region Rb 1 , as the region points of player A. In addition, regarding the game region Rb 1 , the game device correlates the extracted region points (20 points) of player A with the game region Rb 1 , as the region points of player B.
[0054] Similarly, regarding the game region Rc 1 , the game device replaces the extracted region points of player A with the extracted region points of player C, and correlates the replaced region points with the game region Rc 1 . That is, regarding the game region Rc 1 , the game device correlates the extracted region points (30 points) of player C, with the game region Rc 1 , as the region points of player A. In addition, regarding the game region Rc 1 , the game device correlates the extracted region points (20 points) of player A with the game region Rc 1 , as the region points of player C.
[0055] According to an exemplary embodiment, the region points of player A may thus become larger than the region points of another player, in the game region R having the changed region point values, and as such the game device may set the game region R as the corresponding region of player A. In the example of the game field F illustrated in FIG. 2 , the region points (30 points) of player A, which may be correlated with the game region Rb 1 may be larger than the region points of player B and player C, which may be correlated with the game region Rb 1 . Thus, the game device sets the game region Rb 1 as the corresponding region of player A. The region points (30 points) of player A, which may be correlated with the game region Rc 1 may be larger than the region points of player B and player C, which may be correlated with the game region Rc 1 . Thus, the game device may set the game region Rc 1 as the corresponding region of player A. A game region R (in the example illustrated in FIG. 2 , game regions Rb 1 and Rc 1 ) as a target of the region-point changing processing may be referred to as a point-change target region below.
[0056] Hitherto, the descriptions may be made with reference to FIGS. 1A to 2 . In the above-described game device and a control method of the game device, the region-point changing processing may be performed in the domination game. Thus, a player can receive the region points of another player, which may be correlated with a game region R, as the region points of the player, without an operation of designating the game region R. In this manner, it may be possible to realize a domination game requiring a strategy of a player, which may therefore improve the interest in the game by the game device performing the region-point changing processing, and by the control method of the game device. A player who has the largest total amount of the region points when the game may be ended, or has the largest number of corresponding regions may be determined to be the winning player.
[0057] The above descriptions of FIGS. 1A to 2 may be just descriptions for better understanding the details of the present invention. The present invention may be implemented in embodiments which will be described below, and may be implemented in various modification examples in a range without departing from the gist of the present invention. All of such modification examples may be included in the disclosure scope of the present invention and this specification.
[0058] Configuration of Game System 1
[0059] FIG. 3 may be a diagram illustrating an example of a schematic configuration of the game system 1 .
[0060] The game system 1 may include a server 3 and a plurality of portable terminals 2 which may be respectively operated by a plurality of players. The portable terminal 2 and the server 3 may be connected to each other through, for example, a communication network such as a base station 4 , mobile communication network 5 , a gateway 6 , and the Internet 7 . A program (for example, a display processing program) executed in the portable terminal 2 and a program (for example, a region-point changing processing program) executed in the server 3 may communicate with each other by using a communication protocol such as the Hypertext Transfer Protocol (HTTP). The server 3 may be an example of the game device. The game device may not be limited to the server 3 . A portable terminal 2 which has some or all of functions of the server 3 , which will be described later may be used as the game device. The game system 1 including the portable terminal 2 and the server 3 may be used as the game device.
[0061] A multi-function portable phone (so-called a “smart phone”) may be used as the portable terminal 2 , but the present invention may not be limited thereto. As the portable terminal 2 , any device may be provided as long as the present invention can be applied. For example, an information processing device such as a portable phone (a so-called “feature phone”), a portable information terminal (personal digital assistant, PDA), a portable game machine, a portable audio player, a tablet terminal, a tablet PC, and a notebook PC may be provided.
[0062] Configuration of Portable Terminal 2
[0063] FIG. 4 may be a diagram illustrating an example of a schematic configuration of the portable terminal 2 .
[0064] The portable terminal 2 may execute a game such as the domination game, and may be connected to the server 3 through the base station 4 , the mobile communication network 5 , the gateway 6 , and the Internet 7 , so as to communicate with the server 3 . The portable terminal 2 may control the progress of a game in accordance with an operation of an input unit (touch panel and the like) 23 by a player. The portable terminal 2 may receive various types of data from the server 3 , and may control the progress of the game. For this, the portable terminal 2 may include a communication unit 21 , a storage unit 22 , the input unit 23 , a display unit 24 , and a processing unit 25 .
[0065] The communication unit 21 may include a communication interface circuit which may include an antenna having a predetermined frequency band as a reception band. The communication unit 21 may connect the portable terminal 2 to a wireless communication network. The communication unit 21 may establish a wireless signal line by the code division multiple access (CDMA) scheme and the like, between the portable terminal 2 and the base station 4 through a channel allocated by the base station 4 . Thus, the communication unit 21 may communicate with the base station 4 . The communication unit 21 may transmit data supplied from the processing unit 25 to the server 3 and the like. The communication unit 21 may supply data received from the server 3 and the like to the processing unit 25 .
[0066] The storage unit 22 may include a semiconductor memory device, for example. The storage unit 22 may store an operating system program, a driver program, an application program including a game control program, data, and the like which may be used when the processing unit 25 performs processing. For example, the storage unit 22 may store an input device driver program for controlling the input unit 23 , an output device driver program for controlling the display unit 24 , and the like, as the driver program. The storage unit 22 may store a display processing program and the like for progressing the game based on instruction data, data retrieved from the server 3 , and the like, and displaying display data relating to the progress of the game, as the application program. The instruction data may be input by a player operating the input unit 23 . The storage unit 22 may store data retrieved from the server 3 , display data relating to the progress of the game, video data, image data, and the like, as the data. Further, the storage unit 22 may temporarily store temporary data relating to predetermined processing.
[0067] The input unit 23 may be any device as long as the device enables an operation for the portable terminal 2 . For example, a pointing device such as a touch panel may be provided. A player can input a character, a number, a symbol, and the like by using the input unit 23 . If the input unit 23 is operated by a player, the input unit 23 may generate a signal corresponding to the operation. The generated signal may be supplied to the processing unit 25 in accordance with an instruction of the player.
[0068] The display unit 24 may be also any device as long as the device enables display of a video, an image, and the like. For example, a liquid crystal display or an organic electro-luminescence (EL) device may be provided. The display unit 24 may display a video corresponding to video data supplied from the processing unit 25 or may display an image and the like corresponding to image data supplied from the processing unit 25 .
[0069] The processing unit 25 may include one or a plurality of processors and a peripheral circuit. The processing unit 25 may collectively control the overall operation of the portable terminal 2 , and may be a central processing unit (CPU), for example. The processing unit 25 may control operations of the communication unit 21 , the display unit 24 , and the like, so as to perform various types of processing of the portable terminal 2 in appropriate procedures, based on the program stored in the storage unit 22 , an operation of the input unit 23 , and the like. The processing unit 25 may perform processing based on the program (operating system program, driver program, application program, and the like) stored in the storage unit 22 . The processing unit 25 can perform a plurality of programs (application programs and the like) in parallel.
[0070] The processing unit 25 may include at least a display processing unit 251 and an input processing unit 252 . The units may be functional modules realized by a program which maybe executed by a processor included in the processing unit 25 . In addition, the units may be mounted as a firmware in the portable terminal 2 .
[0071] An example of a game screen will be described below with reference to FIGS. 5A to 9B . The game screen may be displayed in display units 24 of a portable terminal 2 a, a portable terminal 2 b, and a portable terminal 2 c which may be respectively held by player A, player B, and player C who participate in the game.
[0072] FIG. 5A may be a diagram illustrating an example of game screens 500 a, 500 b, and 500 c which may be respectively displayed in display units 24 of the portable terminal 2 a, the portable terminal 2 b, and the portable terminal 2 c.
[0073] If the game is started, firstly, the portable terminal 2 a displays a game screen 500 a for causing player A to designate a game region R included in the game field F, in the display unit 24 . The portable terminal 2 b and the portable terminal 2 c may respectively display a game screen 500 b and a game screen 500 c for browsing the game field F, in the display units 24 during a period when the game screen 500 a may be displayed in the display unit 24 of the portable terminal 2 a. A period when the game screen for designating a game region R may be displayed in the display unit 24 of the portable terminal 2 may be referred to as an operable period below.
[0074] FIG. 5B may be a diagram illustrating an example of the game screen 500 a displayed in the display unit 24 of the portable terminal 2 a.
[0075] The game field F and a region-point designation button 501 a which may be operation targets of player A may be displayed on the game screen 500 a. The region-point designation button 501 a may be a button for designating a unit point of the owned points correlated with a game region R, from the owned points associated with player A. For example, in the example of the game screen 500 a illustrated in FIG. 5B , a region-point designation button for one point, a region-point designation button for 10 points, and a region-point designation button for 100 points may be displayed as the region-point designation button 501 a. An example of an operation method of a player for correlating at least a portion of the owned points associated with player A, with a game region R as region points of the game region R will be described below with reference to FIGS. 6A and 6B .
[0076] As illustrated in FIG. 6A , in a case where 30 points of the owned point associated with player A may be correlated with a desired game region Ra, for example, player A may designate the region-point designation button 501 a for 10 points, and may designate the desired game region Ra three times. For example, in a case where player A may cause a region point of five points to be correlated with the desired game region Ra, player A may designate the region-point designation button 501 a for one point, and may designate the desired game region Ra five times. For example, in a case where player A may cause a region point of 200 points to be correlated with the desired game region Ra, player A may designate the region-point designation button 501 a for 100 points, and may designate the desired game region Ra two times. Player A may designate a plurality of game regions Ra for the operable period.
[0077] In the example of the game screen 500 a illustrated in FIG. 6B , the region points may be respectively correlated with four game regions Ra by player A. Because the region points having the largest value may be correlated with the four game regions Ra by player A, the four game regions Ra may be set as the corresponding regions of player A. The corresponding region Ra of player A may be displayed based on predetermined color information associated with player A, so as to enable the region Ra to be distinguished from other game regions R.
[0078] The game field F displayed on the game screen 500 a illustrated in FIGS. 5B, 6A, and 6B may be displayed on the game screens 500 b and 500 c which may be respectively displayed in the display units 24 of the portable terminals 2 b and 2 c, so as to be browsable. The region-point designation button 501 a may not be displayed on the game screens 500 b and 500 c which may be respectively displayed in the display units 24 of the portable terminals 2 b and 2 c, and the game screens 500 b and 500 c may be controlled to cause the game region Ra not to be designated by the players B and C.
[0079] FIG. 7A may be a diagram illustrating an example of game screens 700 a, 700 b, and 700 c which may be respectively displayed in the display units 24 of the portable terminals 2 a, 2 b, and 2 c when a predetermined operable period from when the game screen 500 a may be displayed in the display unit 24 of the portable terminal 2 a may be ended.
[0080] When the predetermined operable period from when the game screen 500 a may be displayed in the display unit 24 of the portable terminal 2 a may be ended, the portable terminal 2 b may display the game screen 700 b in the display unit 24 . The game screen 700 b may be used for causing player B to designate a game region R included in the game field F. The portable terminals 2 a and 2 c may respectively display the game screens 700 a and 700 c for browsing the game field F, in the display units 24 during an operable period when the game screen 700 b may be displayed in the display unit 24 of the portable terminal 2 b.
[0081] FIG. 7B may be a diagram illustrating an example of the game screen 700 b displayed in the display unit 24 of the portable terminal 2 b.
[0082] The game field F and a region-point designation button 701 b which may be operation targets of player B may be displayed on the game screen 700 b. The corresponding region Ra of player A which has been set before the game screen 700 b may be displayed (when the previous operable period may be ended) may be displayed in the game field F. Player B may designate the region-point designation button 701 b, so as to designate a desired game region R. Thus, player B correlates at least a portion of the owned points associated with player B, with the desired game region R, as the region points. Player B may correlate the region points with the corresponding region Ra of player A.
[0083] The game field F displayed on the game screen 700 b illustrated in FIG. 7B may be displayed on the game screens 700 a and 700 c which may be respectively displayed in the display units 24 of the portable terminals 2 a and 2 c, so as to be browsable. The region-point designation button 701 b may not be displayed on the game screens 700 a and 700 c which may be respectively displayed in the display units 24 of the portable terminals 2 a and 2 c, and the game screens 700 a and 700 c may be controlled to cause the game region Ra not to be designated by the players A and C.
[0084] FIG. 8A may be a diagram illustrating an example of game screens 800 a, 800 b, and 800 c which may be respectively displayed in the display units 24 of the portable terminals 2 a, 2 b, and 2 c when a predetermined operable period from when the game screen 700 b may be displayed in the display unit 24 of the portable terminal 2 b may be ended.
[0085] When the predetermined operable period from when the game screen 700 b may be displayed in the display unit 24 of the portable terminal 2 b is ended, the portable terminal 2 c may display the game screen 800 c in the display unit 24 . The game screen 800 c may be used for causing player C to designate a game region R included in the game field F. The portable terminals 2 a and 2 b may respectively display the game screens 800 a and 800 b for browsing the game field F, in the display units 24 during an operable period when the game screen 800 c may be displayed in the display unit 24 of the portable terminal 2 c.
[0086] FIG. 8B may be a diagram illustrating an example of the game screen 800 c displayed in the display unit 24 of the portable terminal 2 c.
[0087] The game field F and a region-point designation button 801 c which may be operation targets of player C may be displayed on the game screen 800 c. The corresponding region Ra of player A and the corresponding region Rb of player B which have been set before the game screen 800 c may be displayed (when the previous operable period may be ended) may be displayed in the game field F. The corresponding region Rb of player B may be displayed based on predetermined color information associated with player B, so as to enable the region Rb to be distinguished from other game regions R and the corresponding region Ra of player A. Player C may designate the region-point designation button 801 c, so as to designate a desired game region R. Thus, player C may correlate at least a portion of the owned points associated with player C, with the desired game region R, as region points. Player C may correlate the region point with the corresponding region Ra of player A and the corresponding region Rb of player B.
[0088] The game field F displayed on the game screen 800 c illustrated in FIG. 8B may be displayed on the game screens 800 a and 800 b which may be respectively displayed in the display units 24 of the portable terminals 2 a and 2 b, so as to be browsable. The region-point designation button 801 c may not be displayed on the game screens 800 a and 800 b which may be respectively displayed in the display units 24 of the portable terminals 2 a and 2 b, and the game screens 700 a and 700 c may be controlled to cause the game region Ra not to be designated by the players A and B.
[0089] FIG. 9A may be a diagram illustrating an example of the game screens 500 a, 500 b, and 500 c which may be respectively displayed in the display units 24 of the portable terminals 2 a, 2 b, and 2 c when a predetermined operable period, from when the game screen 800 c may be displayed in the display unit 24 of the portable terminal 2 c, may be ended.
[0090] When the predetermined operable period from when the game screen 800 c may be displayed in the display unit 24 of the portable terminal 2 c may be ended, the portable terminal 2 a displays the game screen 500 a for causing player A to designate a game region R included in the game field F again, in the display unit 24 . The portable terminals 2 b and 2 c may respectively display the game screens 500 b and 500 c for browsing the game field F, in the display units 24 during an operable period when the game screen 500 a may be displayed in the display unit 24 of the portable terminal 2 a.
[0091] FIG. 9B may be a diagram illustrating an example of the game screen 500 a which may be displayed again in the display unit 24 of the portable terminal 2 a.
[0092] The game field F and a region-point designation button 501 a which may be operation targets of player A may be displayed on the game screen 500 a. The corresponding region Ra of player A, the corresponding region Rb of player B, and the corresponding region Rc of player C which have been set before the game screen 500 a may be displayed again (when the previous operable period may be ended) may be displayed in the game field F. The corresponding region Rc of player C may be displayed based on predetermined color information associated with player C, so as to enable the region Rc to be distinguished from from other game regions R, the corresponding region Ra of player A, and the corresponding region Rb of player B. Player A may designate the region-point designation button 501 a, so as to designate a desired game region R. Thus, player A correlates at least a portion of the owned points associated with player A, with the desired game region R, as the region points.
[0093] Player A may correlate the region points with the corresponding region Ra of player A, the corresponding region Rb of player B, and the corresponding region Rc of player C which have been displayed in the game screen 500 a. In a case where player A sets one or more region points in the corresponding region Ra of player A before the game screen 500 a may be displayed again, the region points which may be designated this time may be added to the region points of player A for the corresponding region Ra, which have been already correlated. Then, the region points of player A, which may be obtained by the addition may be correlated with the corresponding region Ra.
[0094] As described above, a set of the game screens 500 a, 500 b, and 500 c, a set of the game screens 700 a, 700 b, and 700 c, and a set of the game screens 800 a, 800 b, and 800 c may be sequentially displayed in the display units 24 of the portable terminals 2 a, 2 b, and 2 c for each predetermined operable period. Then, the set of the game screens 500 a, 500 b, and 500 c, a set of the game screens 700 a, 700 b, and 700 c, and a set of the game screens 800 a, 800 b, and 800 c may be displayed again in the display units 24 of the portable terminals 2 a, 2 b, and 2 c for each predetermined operable period. In an exemplary embodiment, if a series of processes in which all players who participate in the game perform an input operation in the input operation order for each predetermined operable period is performed the predetermined number of times, the game may be ended.
[0095] FIGS. 10 to 12 may be schematic diagrams illustrating an example of setting the corresponding region Ra of player A, the corresponding region Rb of player B, and the corresponding region Rc of player C.
[0096] In the example of the game field F illustrated in FIG. 10 , 10 points, 20 points, and 30 points may be respectively correlated with the game region Rc 1 , as the region points of player A, player B, and player C. Thus, the game region Rc 1 may be set as the corresponding region of player C.
[0097] 30 points, 20 points, and 10 points may be respectively correlated with the game region Ra 1 , as the region points of player A, player B, and player C. Thus, the game region Ra 1 maybe set as the corresponding region of player A. 20 points, 0 point, and 0 point may be respectively correlated with the game region Ra 2 , as the region points of player A, player B, and player C. Thus, the game region Ra 2 may be set as the corresponding region of player A.
[0098] FIG. 11 illustrates a case where player A further correlates 60 points as the region point, with the corresponding region Rc 1 of player C in the game field F illustrated in FIG. 10 . In this case, a region point of 60 points, which may be correlated this time may be added to the region point of 10 points of player A, which has been already correlated with the corresponding region Rc 1 . Thus, the region point of 70 points of player A after addition may be correlated with the corresponding region Rc 1 .
[0099] FIG. 12 illustrates a display form in a case where a new region point of player A may be correlated with the corresponding region Rc 1 of player C in the game field F illustrated in FIG. 11 . The region point of player A, which may be correlated with the corresponding region Rc 1 may be 70 points which may be larger than the region points of player B and player C. Thus, the corresponding region Rc 1 may be set as a corresponding region Ra 3 of player A. The corresponding region Ra 3 may be displayed based on the predetermined color information associated with player A.
[0100] FIGS. 13 to 16 may be schematic diagrams illustrating an example of the region-point changing processing.
[0101] In the example of the game field F illustrated in FIG. 13 , 30 points, 20 points, and 10 points may be respectively correlated with the game region Ra 1 , as the region points of player A, player B, and player C. Thus, the game region Ra 1 may be set as the corresponding region of player A.
[0102] 30 points, 50 points, and 0 points may be respectively correlated with the game region Rb 1 , as the region points of player A, player B, and player C. Thus, the game region Rb 1 may be set as the corresponding region of player B. 0 points, 0 points, and 70 points may be respectively correlated with the game region Rc 1 , as the region points of player A, player B, and player C. Thus, the game region Rc 1 may be set as the corresponding region of player C.
[0103] 0 points, 0 points, and 0 points may be respectively correlated with the game region Ra 2 , as the region points of player A, player B, and player C. Thus, the game region Ra 2 may not be set as the corresponding region of the players.
[0104] FIG. 14 illustrates a display form in a case where player A correlates 100 points as a new region point, with the game region Ra 2 in the game field F illustrated in FIG. 13 . In this case, the region point of player A may not be correlated with the game region Ra 2 . Thus, the region point of 100 points, which may be correlated this time may be correlated with the game region Ra 2 . Since the region point of player A, which may be correlated with the game region Ra 2 may be 100 points which may be larger than the region points of player B and player C, the game region Ra 2 may be set as the corresponding region of player A.
[0105] FIG. 15 illustrates a case where the game regions Rb 1 and Rc 1 may be arranged between the corresponding region Ra 2 of player A, which may be set this time, and the other corresponding region Ra 1 of player A, which has been previously set.
[0106] In the example illustrated in FIG. 15 , the region points of player A, which may be correlated with the game region Rb 1 , and the region points of player B who has the game region Rb 1 as the corresponding region may be extracted. The extracted region points of 50 points of player B may become region points of player A, with the game region Rb 1 . The extracted region point of 30 points of player A may become the region points of player B, in the game region Rb 1 .
[0107] In addition, the region points of player A, which may be correlated with the game region Rc 1 , and the region points of player C who has the game region Rc 1 as the corresponding region may be extracted. The extracted region points of 70 points of player C may become the region points of player A, with the game region Rc 1 . The extracted region point of 0 point of player A may become the region points of player C, in the game region Rc 1 .
[0108] FIG. 16 illustrates a display form after the region-point changing processing may be performed on the corresponding regions Rb 1 and Rc 1 in the game field F illustrated in FIG. 15 . The region points of 50 points of player A, which may be correlated with the game region Rb 1 may be larger than the region points of 30 points of player B, and the region points of 10 points of player C, which may be correlated with the game region Rb 1 . Thus, the game region Rb 1 may be set as a corresponding region Ra 1 of player A. The region points of 70 points of player A, which may be correlated with the game region Rc 1 may be larger than the region points of 20 points of player B, and the region points of 0 point of player C, which may be correlated with the game region Rc 1 . Thus, the game region Rc 1 may be set as a corresponding region Ra 4 of player A.
[0109] Hitherto, the descriptions may be made with reference to FIGS. 13 to 16 . In the game in which a game region may be correlated with a player, it may be possible to obtain a game region as a corresponding region of a player without the player designating a corresponding region of another player, by the region-point changing processing. That is, a player can acquire the region points of another player, which corresponds to the corresponding region of this player, without directly consuming the owned point for the corresponding region of this player. Thus, it may be possible to provide a game requiring players to exercise a strategy.
[0110] Configuration of Server 3
[0111] FIG. 17 may be a diagram illustrating an example of a schematic configuration of the server 3 . FIGS. 18A to 19B may be diagrams illustrating an example of data structures of various tables stored in a server storage unit 32 .
[0112] The server 3 may include a server communication unit 31 , the server storage unit 32 , and a server processing unit 33 . The server 3 may cause various games such as a domination game to proceed, in accordance with a request from the portable terminal 2 . The server 3 may create display data and the like regarding the progress of the game, and may transmit the created display data to the portable terminal 2 .
[0113] The server communication unit 31 may include a communication interface circuit for connecting the server 3 to the Internet 7 , and may thus perform communication with the Internet 7 . The server communication unit 31 may supply data which has been received from the portable terminal 2 and the like, to the server processing unit 33 . The server communication unit 31 may transmit data supplied from the server processing unit 33 , to the portable terminal 2 and the like.
[0114] The server storage unit 32 may include at least one of a magnetic tape device, a magnetic disk device, and an optical disk device, for example. The server storage unit 32 may store an operating system program, a driver program, an application program, data, and the like which may be used in processing in the server processing unit 33 . For example, the server storage unit 32 may store a game program and the like of causing the game to proceed and creating display data regarding a result, as the application program. For example, the computer program maybe installed on the storage unit 22 from a computer-readable portable type recording medium such as a CD-ROM and a DVD-ROM, by using a well-known set-up program and the like.
[0115] The server storage unit 32 may store a player table illustrated in FIG. 18A , a game field table illustrated in FIG. 18B , and the like, as the data. The server storage unit 32 may store a game table illustrated in FIG. 19A , and may store a region point table illustrated in FIG. 19B . The server storage unit 32 may store various types of image data and the like regarding the progress of the game. Further, the server storage unit 32 may temporarily store temporary data regarding predetermined processing. That is, the server storage unit 32 may include a volatile memory (random access memory, RAM), and may store dynamic data which changes depending on the progress of the game.
[0116] FIG. 18A illustrates the player table for managing a player. A player ID, the name, the owned point, and the like of a player may be stored in the player table for each player, in a state of being associated with each other. The player ID may be an example of identification information for recognizing players at once.
[0117] FIG. 18B illustrates the game field table for managing the game field F. A field ID, game region information, and the like of the game field may be stored in the game field table for each game field, in a state of being associated with each other. The field ID may be an example of identification information for recognizing game fields at once.
[0118] A region ID, a position, and the like of each of a plurality of game regions R included in each game field may be stored in the game region information, in a state of being associated with each other. The region ID may be an example of identification information for recognizing game regions R which may be included in each game field at once. The position may be a position at which each of the game regions R may be disposed in each game field. For example, the position may be two-dimensional coordinates of the center point of each of the game regions R.
[0119] FIG. 19A illustrates the game table for managing a game. A game ID, a field ID, participation player information, and the like of a game may be stored in the game table for each executed game, in a state of being associated with each other. The game ID may be an example of identification information for recognizing games at once. The field ID may be a field ID of a game field used in a game, and may be a field ID stored in the game field table.
[0120] Player IDs of participation players who participate in a game may be stored in the participation player information, in a state of being arranged in an input operation order. In a game, the first player in the input operation order may be referred to as the first player below. The second player, the third player, and the like in the input operation order may be referred to as the second player, the third player, and the like below.
[0121] FIG. 19B illustrates the region point table for managing a region point correlated with a game region R. The region point table may be created for each executed game. The region point table may be stored in association with the game ID of the game. A region ID, region point information, and the like of a game region R may be stored in the region point table for each game region R of a game field F used in the game, in a state of being associated with each other.
[0122] Region points of each game region, which may be respectively correlated by a plurality of players who participate in the game may be stored in the region point information, in a state of being associated with each other. That is, region points of each game region, which may be respectively correlated by the first player, the second player, and the like may be stored in association with each other.
[0123] Returning to FIG. 17 , the server processing unit 33 may include at least a progress control unit 331 , a point retrieval unit 332 , a correlation unit 333 , and a setting unit 334 . The units may be functional modules realized by a program which maybe executed by a processor included in the server processing unit 33 . In addition, the units may be mounted as a firmware in the server 3 .
[0124] An example of the display processing unit 251 and the input processing unit 252 included in the processing unit 25 of the portable terminal 2 , and an example of the progress control unit 331 , the point retrieval unit 332 , the correlation unit 333 , and the setting unit 334 included in the server processing unit 33 of the server 3 will be described below.
[0125] Function of Display Processing Unit 251
[0126] The display processing unit 251 in the portable terminal 2 may display a game screen in the display unit 24 , based on display data which has been received from the server 3 through the communication unit 21 . In a case where the received display data may be display data for displaying a game screen which may be used for causing a player to designate a game region R included in a game field F, the display processing unit 251 may display a region-point designation button along with the game field F. In a case where the received display data may be display data for displaying a game screen which may be used for browsing the game field F, the display processing unit 251 may display the game field F.
[0127] In a case where the owned point of a player who will perform an input operation in the next operable period may be received from the server 3 through the communication unit 21 , the display processing unit 251 may store the received owned point of the player in the storage unit 22 .
[0128] Function of Input Processing Unit 252
[0129] In a case where an instruction to transmit a request of participating in a game provided by the server 3 may be performed by a player operating the input unit 23 , the input processing unit 252 in the portable terminal 2 may transmit a participation request for participating in the game, to the server 3 through the communication unit 21 . The participation request may include the player ID of a player who transmits the participation request, the game ID of a game to be participated, and the like.
[0130] If the game screen for causing a player to designate a game region R included in the game field F may be displayed by the display processing unit 251 , the input processing unit 252 accepts game region designation in an operable period. In accepting processing of the game region designation, firstly, the input processing unit 252 may store region points correlated with a game region R, based on a region-point designation button and the game region R which have been designated by a player operating the input unit 23 . The region points may be stored in the storage unit 22 , in association with the region ID of the game region R. The input processing unit 252 subtracts the correlated region points from the owned point of the player, which may be stored in the storage unit 22 . The input processing unit 252 may store the subtracted owned point in the storage unit 22 . Whenever the owned point maybe subtracted, the display processing unit 251 may display the subtracted owned point on the game screen.
[0131] The input processing unit 252 instructs the display processing unit 251 to end display of the game screen when the operable period may be ended. The input processing unit 252 transmits input data to the server 3 through the communication unit 21 . The transmitted input data may include the player ID of a player who holds the portable terminal 2 , and a region point associated with the region ID stored in the storage unit 22 .
[0132] Function of Progress Control Unit 331
[0133] If a participation request is received from the portable terminal 2 through the server communication unit 31 , the progress control unit 331 in the server 3 may perform game start processing. In the game start processing, firstly, the progress control unit 331 may specify a player ID and a game ID included in the participation request received from the portable terminal 2 . Then, the progress control unit 331 may store the specified player ID in the participation player information of the game table. The specified player ID may be stored as the player ID of a participation player who participates in a game indicated by the specified game ID, in association with the specified game ID. The specified player ID may be stored as the player ID of a participation player, in the participation player information, in an order of receiving the participation request. Then, in a case where there is a game in which the number of persons participating reaches an upper limit which enables participation in the game, with reference to the participation player information of the game table, the progress control unit 331 may start the game. The input operation order for each player, which may be stored in the participation player information may not be limited to the order of receiving the participation request. For example, in a case where the number of persons participating reaches an upper limit which enables participation in the game, with reference to the participation player information of the game table, the progress control unit 331 may randomly line up player IDs included in the participation player information, and may store the list of the player IDs in the participation player information.
[0134] If the game is started, the progress control unit 331 may transmit display data for displaying a game screen of the started game, to portable terminals 2 of players ID included in the participation player information associated with the started game, with reference to the game table. A game field F including a game region R based on game region information which may be extracted from the game field table and relates to a field ID associated with the game ID of the started game may be included in the game screen of the started game. The region-point designation button may be included along with the game field F, in the game screen transmitted to the portable terminal 2 of the first player ID included in the participation player information.
[0135] If the region points for each region ID after the region-point changing processing are stored by the setting unit 334 , the progress control unit 331 may create display data for displaying a game screen. The created display data may be display data for displaying a game screen including the game field F which may include a corresponding region colored based on the region point after the region-point changing processing. The progress control unit 331 may specify the player ID corresponding to the next input operation order among player IDs included in input data, with reference to the game table. The progress control unit 331 may create display data which maybe transmitted to the portable terminal 2 for the specified player ID. In the created display data, the region-point designation button may be included in the game screen.
[0136] The progress control unit 331 may transmit display data to the portable terminal 2 for the player ID corresponding to the next input operation order, and may simultaneously extract the owned point associated with the player ID, from the player table. The progress control unit 331 may transmit the extracted owned point to the portable terminal 2 for the player ID.
[0137] Function of Point Retrieval Unit 332
[0138] The point retrieval unit 332 in the server 3 may retrieve input data which has been received from the portable terminal through the server communication unit 31 . The point retrieval unit 332 may retrieve the player ID of a player, and a region point associated with the region ID. The player ID and the region point may be included in the retrieved input data.
[0139] The point retrieval unit 332 may retrieve region point information associated with the region ID stored in the region point table.
[0140] The point retrieval unit 332 may calculate the summation value of region points which may be respectively associated with region IDs included in the input data received when an operable period may be ended. The point retrieval unit 332 may subtract the calculated summation value from the owned point of the player, which has been stored in the player table. The point retrieval unit 332 may store the subtracted owned point of the player, in the player table.
[0141] Function of Correlation Unit 333
[0142] The correlation unit 333 in the server 3 may add a region point associated with each region ID, to the region point corresponding to the player ID included in input data. The region ID may be included in the input data retrieved by the point retrieval unit 332 . The region point may be stored in the region point information associated with each region ID stored in the region point table. The correlation unit 333 may output a region point after addition. The correlation unit 333 may specify the region ID of a game region R in which the region point value corresponding to the player ID included in the input data may be larger than all region points of other players in the region point after addition, and, in the region point information, the region point value corresponding to the player ID included in the input data may be smaller than region points of all other players, as the current corresponding region ID.
[0143] Function of Setting Unit 334
[0144] If the current corresponding region ID is specified by the correlation unit 333 , the setting unit 334 in the server 3 performs specifying processing of a point-change target region. According to an exemplary embodiment, when specifying processing of a point-change target region, firstly, the setting unit 334 may extract region point information stored in the region point table. Then, the setting unit 334 may specify a region ID of a game region in which a region point corresponding to the player ID stored in the input data may be larger than region points of all other players, as the previous corresponding region ID in the region point information. Then, the setting unit 334 may specify region IDs of game regions disposed in predetermined arrangement, between the current corresponding region ID and the previous corresponding region ID with reference to the game field table. In a case where all of the specified game regions disposed in the predetermined arrangement may be corresponding regions of other players which may be different from the player of the player ID included in the input data, the setting unit 334 may specify the specified game regions disposed in the predetermined arrangement, as point-change target regions. With the above descriptions, the specifying processing of a point-change target region may be ended.
[0145] In a case where the point-change target region is specified by the specifying processing of a point-change target region, the setting unit 334 may perform point change processing. In the point change processing, firstly, the setting unit 334 may extract region point information associated with a region ID of a region-point changing target region, from the region point table. Then, the setting unit 334 may extract the largest region point and a region point corresponding to the player ID included in the input data, in the extracted region point information, for the region ID of the region-point changing target region. Then, the setting unit 334 may generate region point information obtained by replacing the extracted largest region point with the region point corresponding to the player ID included in the input data, for the region ID of the region-point changing target region. The setting unit 334 may store the generated region point information in the region point table.
[0146] Operation Sequence of Game System 1
[0147] FIG. 20 may be a diagram illustrating an example of an operation sequence of the game system 1 . The operation sequence may be executed based on a program which has been stored in advance in the storage unit 22 and the server storage unit 32 . The operation sequence may be mainly executed by the processing unit 25 and the server processing unit 33 , in cooperation with the components of the portable terminal 2 and the server 3 . As an example, an operation sequence of the game system 1 in which the server 3 provides a game in which player A, player B, and player C participate, for the portable terminal 2 a of player A, the portable terminal 2 b of player B, and the portable terminal 2 c of player C will be described below.
[0148] Firstly, the input processing unit 252 in the portable terminal 2 a of player A may transmit a participation request for participating in a game, to the server 3 through the communication unit 21 in accordance with an operation of the input unit 23 by player A (Step S 101 ).
[0149] The input processing unit 252 in the portable terminal 2 b of player B may transmit a participation request for participating in a game, to the server 3 through the communication unit 21 in accordance with an operation of the input unit 23 by player B (Step S 102 ).
[0150] The input processing unit 252 in the portable terminal 2 c of player C may transmit a participation request for participating in a game, to the server 3 through the communication unit 21 in accordance with an operation of the input unit 23 by player C (Step S 103 ).
[0151] In Steps S 101 to S 103 in the operation sequence illustrated in FIG. 20 , the participation requests may be transmitted to the server 3 in an order of the portable terminal 2 a, the portable terminal 2 b, and the portable terminal 2 c. However, the order of transmission may not be limited thereto. That is, processes of Steps S 101 to S 103 may be executed in an order of the participation request being transmitted by the portable terminal 2 .
[0152] Then, if the participation request is received from each of the portable terminal 2 through the server communication unit 31 , the progress control unit 331 in the server 3 may perform the game start processing (Step S 104 ). Descriptions will be made below on the assumption that player A, player B, and player C respectively correspond to the first player, the second player, and the third player.
[0153] Then, the progress control unit 331 may transmit display data for displaying the game screen 500 a which may be used for causing player A to designate a game region R included in the game field F, to the portable terminal 2 a of player A through the server communication unit 31 (Step S 105 ). The progress control unit 331 may transmit the owned point of player A to the portable terminal 2 a of player A through the server communication unit 31 .
[0154] The progress control unit 331 may transmit display data for displaying the game screen 500 b which may be used for browsing the game field F, to the portable terminal 2 b of player B through the server communication unit 31 (Step S 106 ).
[0155] The progress control unit 331 may transmit display data for displaying the game screen 500 c which may be used for browsing the game field F, to the portable terminal 2 c of player C through the server communication unit 31 (Step S 107 ).
[0156] Then, the display processing unit 251 of the portable terminal 2 a may display the game screen 500 a based on the display data which has been received from the server 3 through the communication unit 21 . The input processing unit 252 of the portable terminal 2 a may accept game region designation in an operable period (Step S 108 ). The display processing unit 251 may store the received owned point of player A, in the storage unit 22 before execution of Step S 108 .
[0157] Then, the input processing unit 252 of the portable terminal 2 a may transmit input data which may include a region point correlated with the game region R, to the server 3 through the communication unit 21 (Step S 109 ).
[0158] Then, if the input data may be received from the portable terminal 2 a of player A, the progress control unit 331 , the point retrieval unit 332 , the correlation unit 333 , and the setting unit 334 in the server 3 execute the game progress processing (Step S 110 ). Details of the game progress processing will be described later.
[0159] Then, the progress control unit 331 may transmit display data for displaying the game screen 700 a which may be used for browsing the game field F, to the portable terminal 2 a of player A through the server communication unit 31 (Step S 111 ).
[0160] The progress control unit 331 transmits display data for displaying the game screen 700 b which may be used for causing player B to designate a game region R included in the game field F, to the portable terminal 2 b of player B through the server communication unit 31 (Step S 112 ). The progress control unit 331 may transmit the owned point of player B to the portable terminal 2 b of player B through the server communication unit 31 .
[0161] The progress control unit 331 may transmit display data for displaying the game screen 700 c which may be used for browsing the game field F, to the portable terminal 2 c of player C through the server communication unit 31 (Step S 113 ).
[0162] Then, the display processing unit 251 of the portable terminal 2 b may display the game screen 700 b based on the display data which has been received from the server 3 through the communication unit 21 . The input processing unit 252 of the portable terminal 2 b may accept game region designation in an operable period (Step S 114 ). The display processing unit 251 may store the received owned point of player B, in the storage unit 22 before execution of Step S 114 .
[0163] Then, the input processing unit 252 of the portable terminal 2 b may transmit input data which may include a region point correlated with the game region R, to the server 3 through the communication unit 21 (Step S 115 ).
[0164] Then, if the input data is received from the portable terminal 2 b of player B, the progress control unit 331 , the point retrieval unit 332 , the correlation unit 333 , and the setting unit 334 in the server 3 may perform the game progress processing (Step S 116 ). Details of the game progress processing will be described later.
[0165] Then, the progress control unit 331 may transmit display data for displaying the game screen 800 a which may be used for browsing the game field F, to the portable terminal 2 a of player A through the server communication unit 31 (Step S 117 ).
[0166] The progress control unit 331 may transmit display data for displaying the game screen 800 b which may be used for browsing the game field F, to the portable terminal 2 b of player B through the server communication unit 31 (Step S 118 ).
[0167] The progress control unit 331 may transmit display data for displaying the game screen 800 c which may be used for causing player C to designate a game region R included in the game field F, to the portable terminal 2 c of player C through the server communication unit 31 (Step S 119 ). The progress control unit 331 may transmit the owned point of player C to the portable terminal 2 c of player C through the server communication unit 31 .
[0168] Then, the display processing unit 251 of the portable terminal 2 c may display the game screen 800 c based on the display data which has been received from the server 3 through the communication unit 21 . The input processing unit 252 of the portable terminal 2 c may accept a game region designation in an operable period (Step S 120 ). The display processing unit 251 may store the received owned points of player C, in the storage unit 22 , before execution of Step S 120 .
[0169] Then, the input processing unit 252 of the portable terminal 2 c may transmit input data which may include a region point correlated with the game region R, to the server 3 , through the communication unit 21 (Step S 121 ).
[0170] Then, if the input data is received from the portable terminal 2 c of player C, the progress control unit 331 , the point retrieval unit 332 , the correlation unit 333 , and the setting unit 334 in the server 3 may perform the game progress processing (Step S 122 ). Details of the game progress processing will be described later.
[0171] After that, the above-described processes of Step S 105 to Step S 122 may be executed until each of the portable terminals 2 performs the game region designation the number of times, which may be preset by the server 3 .
[0172] Game Progress Processing
[0173] FIG. 21 may be a diagram illustrating an example of an operation flow of the game progress processing performed by the progress control unit 331 , the point retrieval unit 332 , the correlation unit 333 , and the setting unit 334 . The game progress processing illustrated in FIG. 21 may be executed in the processes of Steps S 110 , S 116 , and S 122 in FIG. 20 .
[0174] Firstly, the point retrieval unit 332 may retrieve the player ID of a player and a region point associated with a region ID, from the input data which has been received from the portable terminal 2 through the server communication unit 31 (Step S 201 ). The point retrieval unit 332 may retrieve region point information associated with the region ID stored in the region point table. In Step S 201 , the point retrieval unit 332 may store the subtracted owned point of the player, in the player table, based on the summation value of region points associated with the region ID included in the input data.
[0175] Then, the correlation unit 333 may calculate a region point after addition, and may specify the current corresponding region ID (Step S 202 ).
[0176] Then, if the current corresponding region ID may be specified, the setting unit 334 may perform the specifying processing of a point-change target region (Step S 203 ).
[0177] Then, the setting unit 334 may determine whether or not the point-change target region may be specified by the specifying processing of a point-change target region (Step S 204 ).
[0178] In a case where no point-change target region is specified (No in Step S 204 ), the setting unit 334 may cause the process to proceed to Step S 207 .
[0179] In a case where the point-change target region is specified (Yes in Step S 204 ), the setting unit 334 may perform the region-point changing processing (Step S 205 ).
[0180] Then, the setting unit 334 may store the region point after the region-point changing processing, as region point information of the region point table for each region ID (Step S 206 ). In a case where the last game progress processing in the executed game is performed, the process of Step S 206 may be executed, and a series of steps may be ended.
[0181] The progress control unit 331 may create display data for displaying a game screen which may include the game field F including the corresponding region colored based on the region point information of the region point table (Step S 207 ), and may then end a series of steps.
[0182] Hitherto, as described above in detail, the game system performs the region-point changing processing in a domination game. Thus, a first player can have the region points of another player, which may be correlated with a game region R, as the region points of the first player without designating the game region R. Thus, it may be possible to realize a game requiring a player to exercise a strategy, improving the player's interest for the game. In the above descriptions, as an example, the descriptions may be made by using player A, player B, and player C as players participating in the game. However, the number of players participating in the game may not be limited to three. The shape of the game region may be any shape.
MODIFICATION EXAMPLE 1
[0183] In receiving processing of game region designation by the input processing unit 252 of the portable terminal 2 , predetermined designation conditions may be associated with a plurality of game regions R included in the game field F which may be used in the game.
[0184] FIG. 22A may be a schematic diagram illustrating another example of the game field F used in the game.
[0185] In the example of the game field F illustrated in FIG. 22A , a game region Rx which does not function as the point-change target region may be disposed in the game field F. The game system 1 may associate a condition in that, in a case where a player correlates a region point with the game region Rx, a first predetermined point value may be consumed from the owned points of the player, with the game region Rx, as the predetermined designation condition. For example, in the game region information of the game field table, the first predetermined point value may be associated and stored in correlation with the region ID of a game region Rx. In a case where a game region R designated by a player operating an input unit 23 may be the game region Rx, the input processing unit 252 may consume the correlated region point(s) and the first predetermined point value associated with the region ID of the game region Rx, from the owned point of the player, which may be stored in the storage unit 22 .
[0186] In this manner, in a case where a game region Rx of which a probability of being included in the predetermined arrangement may be lower than that of another game region R may be a region at an end portion of all game regions R included in the game field F, if a region point may be correlated with the game region Rx by a player, the correlated region point and the first predetermined point value associated with the game region Rx may be consumed from the owned point of the player.
[0187] The game region Rx of which a probability of being included in the predetermined arrangement may be lower than that of another game region R may not be limited to the game region Rx illustrated in FIG. 22A . For example, a game region R may be set as the game region Rx, in accordance with the number of other game regions R which may be adjacent to the game region R. In this case, for each game region R, the number of other game regions R which may be adjacent to each game region R may be calculated, and the first predetermined point value may be given a value depending on the calculated value that may be associated with each game region R. That is, in a case where one other game region R may be adjacent to a game region Rx, the first predetermined point value may be 100 points, for the game region Rx. In a case where two other game regions R may be adjacent to a game region Rx, the first predetermined point value may be 50 points, for the game region Rx. The first predetermined point value associated with a game region Rx may be calculated by a predetermined calculation expression (for example, 100/(the number of other game regions R which may be adjacent to the game region Rx)).
[0188] Thus, it may be possible to provide a game in which stimulation may be performed such that a case where game region R having a high probability of being included in the predetermined arrangement may be designated by a player occurs relatively frequently, and in which forming a point-change target region or predetermined arrangement may be promoted, and an occurrence of stalemate may be difficult. It may be possible to prevent an occurrence of a situation in which a player having the owned point of a value larger than that of other players correlates a large amount of region points with a game region Rx, in advance, and to prevent reduction of the will of other players to continue the game. The game region Rx may be an example of a first specific region.
[0189] In the example of the game field F illustrated in FIG. 22A , a condition relating to the upper limit of the region point correlated with the game region Rx by a player may be associated with the game region Rx, as the predetermined designation condition. For example, in the game region information of the game field table, a second predetermined point value may be associated and stored in correlation with the region ID of the game region Rx. In a case where the game region R designated by a player operating an input unit 23 may be the game region Rx, the input processing unit 252 may control correlation of the region point, so as to cause the summation value of region points of players, which may be correlated with the game region Rx, not to exceed the second predetermined point value. For example, in a case where designation of the game region Rx may be received, if it may be determined that the summation value of region points of players, which may be correlated with the game region Rx exceeds the second predetermined point value, the input processing unit 252 may cancel the received designation input.
[0190] Thus, it may be possible to prevent an occurrence of a situation in which a player correlates a large amount of region points with a game region Rx, in advance, which may help to prevent other players from losing the will to continue the game.
MODIFICATION EXAMPLE 2
[0191] The progress control unit 331 in the server 3 may change the game field F displayed by display data transmitted to the portable terminals 2 , in accordance with the progress of the game.
[0192] FIG. 22B may be a schematic diagram illustrating an example of the game field F used in the game.
[0193] In the example of the game field F illustrated in FIG. 22B , a restricted region Rt may be disposed in the game field F. It may not be possible for a player to designate the restricted region Rt at a time of starting the game. In a case where the restricted region Rt may be included in the game field F, the display processing unit 251 in the portable terminal 2 generally does not display the restricted region Rt, and but displays only game regions R included in the game field F.
[0194] Then, the progress control unit 331 in the server 3 may determine whether or not a predetermined game-field change condition may be satisfied, in accordance with game region designation of a player who participates in the game. Then, in a case where the predetermined game-field change condition is satisfied, the progress control unit 331 may change some of the restricted regions Rt to game regions R, and may create display data for displaying a game screen including a game field F which may include the changed game region R. The progress control unit 331 may transmit the created display data to the portable terminal 2 .
[0195] For example, the predetermined game-field change condition may correspond to a case where the number of times of performing a series of processes in which all players participating in the game performs an input operation in an input operation order exceeds the predetermined number, or to a case where a region point may be correlated with a specific game region (game region and the like which may be adjacent to the restricted region Rt) by a player. The predetermined game-field change condition may correspond to a case where the number of game regions R correlated with a region point by all players participating in the game or by a specific player exceeds the predetermined number of regions, a case where the summation value of region points correlated with all or some of game region R among the game regions R correlated with region points exceeds a third predetermined point value, or a case where a predetermined period elapses from when the game may be started.
[0196] The game field F may not be limited to the example illustrated in FIG. 22B . For example, the game field F may include a first sub-game field F 1 , a second sub-game field F 2 , and a restricted region Rt. The first sub-game field F 1 may include a plurality of first game regions R 1 . The second sub-game field F 2 may include a plurality of second game regions R 2 . The restricted region Rt may be disposed between the first sub-game field F 1 and the second sub-game field F 2 . In this case, if the restricted region Rt may be changed to a game region R, the restricted region Rt may be disposed on a game field F so as to cause the first sub-game field F 1 and the second sub-game field F 2 to form one game field F.
[0197] In a case where the above-described predetermined game-field change condition is satisfied, the progress control unit 331 may change the predetermined game region R to the restricted region Rt. In this case, in a case where the predetermined game-field change condition may be satisfied, the progress control unit 331 may change at least some of the game regions R to restricted regions Rt, and may create display data for displaying a game screen including a game field F which may include the changed game region R. The progress control unit 331 may transmit the created display data to the portable terminal 2 . The restricted region Rt may be displayed so as to be visually recognizable or not to be visually recognizable. In a case where a region point may be correlated with the game region R which has been changed to the restricted region Rt, the correlated region point may be included in the owned point of a player who correlates the region point.
[0198] In a case where the above-described predetermined game-field change condition is satisfied, the progress control unit 331 may change the predetermined game region R to an undesignatable region Ro. The undesignatable region Ro may be a game region in which it may not be possible that a player correlates a region point, and a game region which does not function as the point-change target region. In a case where a region point may be correlated with a game region R which has been changed to the undesignatable region Ro, the correlated region point may be maintained without being changed. The region point correlated with the undesignatable region Ro may be used in the progress of the game (for example, determination of win or lose of the game), similarly to a region point correlated with a general game region R. An undesignatable period in which the predetermined game region R may be changed to the undesignatable region Ro may be set in the game system 1 . In this case, if a predetermined undesignatable period elapses from when the predetermined game region R may be changed to the undesignatable region Ro, the undesignatable region Ro may be brought back into a game region R.
[0199] With the above descriptions, it may be possible to provide a game requiring further strategy from a player, in that a game region R on which play can occur may be selected and periodically updated, while the change of the game field F may be predicted. In addition, it may be possible to provide a game in which a player may be prevented, in advance, from associating a large amount of region points with a game region Rx, and in which an a stalemate may be unlikely to occur.
MODIFICATION EXAMPLE 3
[0200] In the embodiment, each of a plurality of players may be able to designate a game region R at any time during the operable period corresponding to the player. However, a period or a timing when a player can designate a game region R may not be limited to the operable period. For example, control may be performed such that a timing when a player can designate a game region R has a predetermined time interval, in a period from a start of the game to an end of the game. That is, a player can designate the next game region R after a predetermined time interval from a timing when at least some of the owned points of the player may be correlated with a game region R. In this case, the predetermined time interval may be changed in accordance with the size of the points value of region points associated with a game region R by the player. For example, control may be performed such that the predetermined time interval becomes longer as the value of the point which has been correlated as a region point, with a game region R by a player. Thus, it may be possible to cause region points which can be correlated with game regions R by each player to be uniform. In addition, an occurrence of a situation in which a player who has a large amount of the owned point may be too advantageous may be prevented, and thus it may be possible to maintain the will of a player to continue the game even when that player does not have a large amount of the owned points, to continue the game. It may be possible to provide a game in which considering the amount of a region point correlated with a game region R by a player and an operable period of the player, in accordance with an action of a player as the competition opponent may be required, and strategic characteristics may be required.
MODIFICATION EXAMPLE 4
[0201] The game system 1 may progress a game in which game regions included in the game field F may be respectively designated by a plurality of players and thus the game regions R may be correlated with groups to which the plurality of players belongs.
[0202] FIG. 23 may be a diagram illustrating another example of the schematic configuration of the game system 1 . As an example, a game in which a plurality of groups (group G 1 , group G 2 , and group G 3 ) to which players participating in the game belong may be correlated with a game region R will be described below.
[0203] As illustrated in FIG. 23 , a correlation game such as a domination game, in which a game field F including a plurality of game regions R may be displayed in portable terminals 2 of players who participate in the game and belong to a group G 1 , a group G 2 , and a group G 3 , and the displayed game field F may be used may proceed by the portable terminal 2 and the server 3 constituting the game system 1 .
[0204] Each of a plurality of players participating in the game may designate a game region R included in the displayed game field F, in an input operation order. The input operation order may be correlated with the group. For example, in a case where the first in the input operation order may be the group G 1 , each of players belonging to the group G 1 may designate a game region R in the operable period of the first in the input operation order. Similarly, in a case where the second in the input operation order may be the group G 2 , each of the players belonging to the group G 2 may designate a game region R in the operable period of the second in the input operation order.
[0205] Then, the server 3 may receive input data from the portable terminal 2 of a player belonging to each group in the input operation order, when each operable period in the input operation order may be ended. Each group in the input operation order may be an example of a first group. The server 3 may calculate the summation value of region points correlated by players belonging to a group in each of a plurality of game regions R, and may correlate the calculated summation value of each of the game regions, as a game point of the group in each of the game regions.
[0206] The server 3 sets each of the plurality of game regions R, as a corresponding region of the group, which may be correlated with a region point of a value which may be the largest among region points correlated with the game region R.
[0207] The server 3 may specify another corresponding region Ra 1 of the group, which has been previously set, and may be different from the corresponding region Ra 2 of the group, which may be set this time in the input operation order. Then, the server 3 may determine whether or not one or a plurality of game regions R may be disposed between the corresponding region Ra 2 of the group, which has been set, and the specified other corresponding region Ra 1 of the group, in predetermined arrangement.
[0208] In a case where it may be determined that one or the plurality of game regions R may be disposed in the predetermined arrangement, the server 3 may determine whether or not all of the determined game regions R may be corresponding regions of another group which may be different from the group of this time in the input operation order. Then, in a case where it may be determined that all of the game regions R disposed in the predetermined arrangement may be the corresponding regions of another group, the server 3 may extract a region point of the group of this time in the input operation order, which may be correlated with the game region R disposed in the predetermined arrangement, and may extract a region point of another group which has the game region R disposed in the predetermined arrangement, as the corresponding region.
[0209] The server 3 may replace the extracted region point of the group of this time in the input operation order with the extracted region point of another group, and may store the region points replaced with each other.
[0210] In this manner, in a game in which the region-point changing processing may be performed, it may be possible to execute a competition between groups to which a plurality of players belongs, and to improve more interest for the game. Each player belonging to a group has a need to progress the game in cooperation with other players belonging to the group, and thus it may be possible to further promote cooperation in the group. In the embodiment and other modification examples, the region point and the corresponding region may be set for each group, and the region-point changing processing may be performed for each group.
[0211] A player belonging to each group may correlate a region point with a game region R, in accordance with an operation condition which has been set for each group. For example, the operation condition may correspond to a case where the summation of region points which can be correlated with a game region R by players belonging to each group, in each operable period, may be equal to or less than the predetermined first conditional value. Additionally or alternatively, the operation condition may correspond to a case where the summation of the number of game regions R which can be correlated with region points by players belonging to each group, in each operable period, may be equal to or less than the predetermined second conditional value.
[0212] For example, in a case where the first conditional value may be 1000 points, if the summation value of region points correlated by all players belonging to each group reaches 1000 points in the operable period of each group, it may not be possible that the player belonging to the group correlates a region point with a game region R until the next operable period. In a case where the second conditional value may be 50 pieces, if the summation value of the number of game regions R correlated by all players belonging to each group reaches 50 pieces in the operable period of each group, it may not be possible that the player belonging to the group correlates a region point with a game region R until the next operable period.
[0213] The operation condition may correspond to a case where the summation of region points which can be correlated with a game region R by players belonging to each group, for a period from a start of the game to an end of the game, may be equal to or less than a third predetermined conditional value. Additionally or alternatively, the operation condition may correspond to a case where the summation of the number of game regions R which can be correlated with a region point by a players belonging to each group for a period from a start of the game to an end of the game may be equal to or less than a fourth predetermined conditional value, and the like. The first conditional value, the second conditional value, the third conditional value, and the fourth conditional value may vary for each group.
[0214] Thus, each player belonging to a group has a need to progress the game in cooperation with other players belonging to the group, and thus it may be possible to further promote cooperation in the group.
MODIFICATION EXAMPLE 5
[0215] The progress control unit 331 in the server 3 may associate each player with a player reward in accordance with the region point correlated with a game region R by each player participating in the game. The player reward may be game content, an item, virtual currency, or the like which may be used in another game, another event, and the like.
[0216] For example, the progress control unit 331 may store a region point included in the input data transmitted by each player, in the server storage unit 32 . When the game may be ended, the progress control unit 331 calculates the summation value of the region points of the player, which have been stored in the server storage unit 32 . The player reward depending on the calculated summation value may be stored in the server storage unit 32 in association with each player. The summation value may be a summation value of region points for corresponding regions of each player when the game maybe ended.
[0217] The progress control unit 331 may associate the group reward with each player, in accordance with the region point correlated with the corresponding region of a group to which each of players participating in the game belongs. The group reward may be game content, an item, virtual currency, or the like which may be used in another game, another event, and the like. The group reward may be different from the player reward.
[0218] For example, when the game may be ended, the progress control unit 331 may calculate the summation value of the region points correlated with the corresponding regions of each player, which have been stored in the server storage unit 32 , for each group. The group reward depending on the calculated summation value of the region points of each group may be stored in the server storage unit 32 in association with each player belonging to each group. The summation value may be a summation value of the region points correlated with the corresponding regions of a group to which each of the players belongs, or be a summation value of the region points of each group, which may be correlated with game regions R by each of the players participating in the game, in the middle of executing the game.
[0219] Thus, in a group competition in the correlation game such as a domination game, it may be possible to obtain a reward depending on an individual record or a reward depending on the degree of the group participating in the game, in addition to a competition result. Thus, it may be possible to further improve player interest in the game. Because each player participates in the game while simultaneously having to consider a strategy for improving an individual record and a strategy for improving a group record, players' interest may be held for longer and the game may be vitalized.
MODIFICATION EXAMPLE 6
[0220] The corresponding region R of a player may be displayed based on predetermined color information associated with the player. However, the predetermined color information may be changed in accordance with the region point of the player, which may be correlated with the corresponding region R, and the corresponding region R may be displayed based on the changed color information. For example, the progress control unit 331 in the server 3 may specify predetermined color information associated with a player. The progress control unit 331 changes brightness, chroma, or hue in the predetermined color information in accordance with the region point of the player, which may be correlated with the corresponding region R of the player. The progress control unit 331 may create display data for displaying a game screen including the game field F which may include the corresponding region R, based on the changed color information.
[0221] In the corresponding region R of a player, the predetermined color information associated with the player may be changed in accordance with the region point of another player, which may be correlated with the corresponding region R. The corresponding region R may be displayed based on the changed color information.
[0222] In the corresponding region R of a player, predetermined color information associated with the player may be changed in accordance with the region point of the player, which may be correlated with the corresponding region R and the region point of another player. The corresponding region R may be displayed based on the changed color information. For example, a relative point such as a different value between the region point of the player and the region point of another player may be calculated, and predetermined color information may be changed in accordance with the calculated relative point.
[0223] Thus, it may be possible to easily visually recognize a region point correlated with a corresponding region R by a player and/or other players, and to determine a game region which may be immediately correlated by the player.
[0224] In the portable terminal 2 held by a player, a corresponding region R of the player may be displayed based on first color information, and corresponding regions R of all other players except for the player may be displayed based on second color information. Thus, the player can immediately distinguish the own corresponding region R from corresponding regions R of other players except for the player. The portable terminal 2 held by a player may have a function of performing switching between display of a corresponding region based on color information associated with each of a plurality of players, and display of corresponding regions based on first color information for the player and second color information for all other players. Thus, it may be possible to display a corresponding region in a display form desired by a player.
MODIFICATION EXAMPLE 7
[0225] In a case where a predetermined period elapses from a start of the game, the progress control unit 331 in the server 3 may end the game. In a case where the summation value of region points correlated with a game region by players participating in the game exceeds a predetermined value, the progress control unit 331 may end the game.
[0226] Thus, the game may be ended at a timing which may not be expected by a player, and thus it may be possible to provide a game further requiring a strategy of a player.
MODIFICATION EXAMPLE 8
[0227] The above-described functions of the server processing unit 33 may be executed in the processing unit 25 in the portable terminal 2 . In this case, if various tables may be stored in the storage unit 22 , it may not be necessary that a communication with the server 3 may be performed every time processing may be performed, and the above functions can be realized only by the portable terminal 2 . The game executed in the portable terminal 2 may be a hybrid-game in which the server 3 and the portable terminal 2 handle a portion of the processing. In this case, for example, web display and a native display may be provided. In the web display, the game screen relating to the progress of the game may be displayed in the portable terminal 2 based on display data generated by the server 3 . In the native display, others of a menu screen and the like may be displayed by a native application which may be installed on the portable terminal 2 .
MODIFICATION EXAMPLE 9
[0228] The game system 1 may have a configuration of including only a plurality of portable terminals 2 which may be respectively operated by a plurality of players. Each of the plurality of portable terminals 2 may perform wireless communication with other portable terminals 2 by a wireless communication scheme of the IEEE802.11 standards. The plurality of portable terminals 2 may constitute an ad hoc network. In this case, a specific portable terminal 2 among the plurality of portable terminals 2 may function as a host, and may execute the above-described functions of the server 3 . A portable terminal 2 other than the specific portable terminal 2 among the plurality of portable terminals 2 may communicate with the specific portable terminal 2 that executes the functions of the server 3 , and thus the above-described game may be executed. The specific portable terminal 2 functioning as the host may execute both of the functions of the server 3 and the functions of the portable terminal 2 .
[0229] The skilled person of the related art can understand that various changes, substitutions, and modifications maybe added without departing from the gist and the scope of the present invention. | A control program for a game device having a storage unit configured to store points associated with players. The game device may receive a request by a player to designate at least a portion of the points associated with the first player as region points of the first player, which may in turn be correlated with a game region designated by the first player. When the first player has the most points for a particular game region, the game region may be set to be a region of the first player. When the first player disposes a first and second game region in a predetermined arrangement, such that the first and second game region has game regions between them, the game regions between the first and second game region may have their point values swapped to put the first player on top. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a device for displaying fishing reels for greatest sales appeal with least risk of theft or damage.
Customers of self-service stores are generally given full opportunity to handle and examine displayed store merchandise without the attention of store personnel. This method of merchandising reduces the cost of sale and, therefore, reduces the price charged to customers. Since a typical self-service store is large in terms of floor space, enjoys dense customer traffic, and is not designed or staffed for close observation of customer activity, uncommonly high levels of shoplifting and damage of openly displayed merchandise tend to reduce or eliminate the cost advantage of self-service stores over full-service stores. This dilemma is particularly acute in the case of fishing reels because a prospective buyer expects to be able to spin the reel's crank, check its drag and brake, and otherwise handle and operate the reel to gain some sense of its quality, performance and manual feel. However, such relatively expensive display reels are easily damaged by rough handling and are sufficiently compact to be readily concealed and removed from the store premises by a shoplifter.
Heretofore, fishing reels have been displayed using various methods and apparatus none of which reduces the aforedescribed risks of damage and theft to acceptable levels. For example, the display of reels by placing them loosely together on counter tops or in bins subjects such reels to breakage due to being dropped or pushed from the counter and due to reel parts becoming entangled and thereafter damaged by careless customers. Furthermore, even when reels displayed in this manner are secured by safety cables or chains, they are easily stolen by cutting the safety device or detaching it from the reel or the counter with a simple tool.
To avoid damage and theft encountered when reels are loosely displayed, it has been proposed to secure several makes and models of reels to a pipe rack or frame by means of ordinary band-type pipe clamps which overlie the extending feet of the reel pedestal thereby securing them in clamped engagement with a pipe. In practice this display method is highly unsatisfactary due to difficulties encountered by customers attempting to operate the reel, the extreme ease of removal of reels from such clamps, the added risk of injury to customers coming in contact with protruding clamp components, and the crude appearance of the pipes and pipe clamps.
It has also been proposed to mount display reels on individual handle portions of fishing rods, or on an approximation of such handle portion, with the rod end of the handle portion fastened to and projecting from an upstanding panel or partition. Prior U.S. Pat. Nos. 4,378,882 and 4,560,071 suggest this approach; however, neither prior patent shows an effective means for thwarting theft of a reel from the handle since nothing more than conventional keeper rings or nuts are disclosed for securing the reel to the handle. If a reel were shomehow nonremovably attached to the handle of these prior devices, a determined thief could quite easily remove both handle and reel from a display panel by simply detaching the handle from the panel or by breaking off the handle.
SUMMARY OF THE INVENTION
Accordingly, it is the principal object of this invention to provide a panel-mounted store display device for fishing reels which facilitates inspection and handling of such merchandise by customers while reducing to a minimum the risks of damage and theft.
Another important object is to provide an extremely rugged, yet simply and economically constructed mount for display reels which is operable to clamp the extending feet of a reel pedestal to the mount as an incident to drawing the mount into compressive engagement with the front face of a display panel. To this end a rear portion of the mount penetrates through and beyond a receiving aperture in the panel and cooperates with attaching means located rearwardly of the panel to draw and retain the mount in fixed relation with the panel at the same time causing the reel feet portions to be engaged and held by clamping sleeves slideably carried by a front portion of the mount. By locating the attachment means for the mount behind the panel with the reel clamped to the mount projecting outwardly from the front side of the panel, the attachment means is isolated from unwanted tampering intended to remove the reel from the mount or the mount from the panel.
Still another object is to provide an elongated reel mount of the aforedescribed character which is removably attachable to an upstanding flat panel with the mount's longitudinal centerline sloped with respect to the panel face and with the outer end of the mount being gyratory about its point of attachment to the panel. A related object is to provide for attachment of the mount in variable angular relationships to the panel face whereby different types of reels clamped to the mount may be oriented, with respect to the front face of the panel and the mount itself, for optimum visibility, accessability and operbility from a customer position in front of the panel. In the case of a typical casting reel, such optimization is achieved by clamping the reel on top of a mount projecting outwardly and downwardly from the panel at the 6 o'clock position; and, in the case of a typical spinning reel, best results are obtained with the reel clamped below a mount projecting outwardly and upwardly from the panel at the 12 o'clock position.
Yet another object is to provide a reel mount of simple design which can be manufactured at extremely low cost yet is sufficiently strong to resist the most strenous manual efforts to remove a reel clamped to the mount or to break off the mount or pull the mount itself from the panel to which it is fastened. In spite of the rugged character of a mount constructed in accordance with this invention, the conformation of the mount is pleasing to the eye and adds to the overall visual appeal of the reel display.
A still further object is to provide a sizable display panel for carrying a multitude of reel mounts in spaced array. Such panel may advantageously comprise the sloping front wall of an upstanding case or cabinet access to which is controlled by store personnel. In this manner the means for securing the mounts to the display panel are isolated inside the cabinet and are, therefore, inaccessable to shoplifters.
These and other features and objects of this invention and the manner of attaining them will become apparent and the invention will be best appreciated and fully understood by having reference to the following detailed description of an embodiment of the invention taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side view of two identical reel mounts attached to a display cabinet;
FIG. 2 is an enlarged, fragmentary sectional view of the mount and reel shown in the lower portion of FIG. 1;
FIG. 3 is a cross-section taken along lines 3--3 of FIG. 2;
FIG. 4 is a cross-section taken along lines 4--4 of FIG. 2; and,
FIG. 5 is a cross-section taken along lines 5--5 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Two identical reel mounts, indicated in their entireties by numerals 10a and 10b in FIG. 1, are attached to and project from the front of an upstanding display cabinet 12. The lower mount 10a carries thereon a typical spinning reel 14 while a typical casting reel 16 is clamped to the upper mount 10b. As will be more fully disclosed hereinafter, the cabinet 12 may be provided with a large front closure panel 12a having sufficient area for a displayed array of reels of different types, sizes and makes.
The reels 14 and 16 represent the two types of reels which enjoy the largest markets in self-service stores; however, it will be clear from the following description that other types of reels can be advantageously displayed on the mounts and cabinet disclosed herein. Although the structural and operational details of both types of reels vary according to size, model and source of manufacture, the typical spinning reel 14 essentially comprises a body 14a, a pedestal 14b, tapered mounting feet 14c extending perpendicularly at the free end of the pedestal, a reeling crank 14d, a retractable bail 14e and a drag actuater 14f; and, the typical casting reel 16 essentially comprises a body 16a, a pedestal 16b, mounting feet 16c, a reeling crank 16d, and a brake actuator 16e. The depicted reels are attached to mounts 10a and 10b, respectively, in the same relationship as such reels would be mounted on actual spinning or casting rods. Thus, spinning reel crank 14d is located to the left-hand side of the longitudinal centerline of mount 10a, as viewed by a customer looking to the cabinet 12 from a position at the right-hand side of FIG. 1. On the other hand, casting reel body 16a rests above mount 10b on pedestal 16b while crank 16d is located on the right-hand side of mount 10b.
In the preferred cabinet construction, the front panel 12a is sloped from vertical toward the rear of the cabinet through an angle A. The reel mounts 10a, 10b do not extend perpendicularly from the flat front panel surface 12b, but slope at angles B and C, respectively, whereby mount 10a is elevated above horizontal through an angle equal to the sum of angles A and B while mount 10b is depressed from horizontal through an angle equal to the difference between angle C and angle A. Aided by practical experimentation, the angles A, B and C were selected to optimize visual inspection and manual handling and operation of the reels 14 and 16 by a customer even where a multiplicity of reels are compactly mounted on panel 12a in vertically and horizontally extending rows. Thus angle A is preferably about 15° whereby the exterior features of any reels mounted below the vertical midpoint of a typical panel 12a are more readily visible to a customer standing near to and facing the front panel surface 12b. Preferably the angles B and C are equal and are about 45° . Thus the mount 10a extends 60° up from horizontal and mount 10b extends 30° down from horizontal. A mount orientation of this type displays features of both reels to greater advantage than would be the case if the mounts 10a and 10b projected perpendicularly from the panel face 12b. Moreover, since the angles adjacent selected angles B and C are 135°, sufficient space is provided between the respective mounts 10a and 10b and panel surface 12b to accommodate reel 14 which must underlie mount 10a and reel 16 which must overlie mount 10b in order to situate the respective cranks and controls of the reels in a natural location expected by a customer handling the reels. The principal advantage of making angles B and C alike is to facilitate interchangeability of mounts and reversibility of an individual mount from the 12 o'clock attitude of mount 10a to the 6 o'clock attitude of 10b, and vice versa.
Having described the preferred angularity and orientation of the mounts 10a and 10b with respect to typical reels 14 and 16 and with respect to a preferred display cabinet 12, the structure and mode of operation of the mount itself will be described in detail having reference principally to mount 10a since it is shown in detail in FIGS. 2 through 5.
The mount 10a includes an elongated shaft 18 which is threaded along the major portion of its length and which terminates at its free end or forward end in an enlarged, convex head 18a while its rear end 18b is extendable through an aperture 12c in the panel 12a. A intermediate portion of shaft 18 is disposed interiorly of a surrounding tubular clamping rod or bar 20 which in nonrotatably fixed to the shaft 18 at one end 20a, by welding or the like. The shaft has a round cross-section while the bar 20 is square in cross-section; and, as best shown in FIGS. 3 and 4, only slight clearance is provided between the exterior surface of shaft 18 and the interior wall surfaces of bar 20. The bar 20 is longitudinally fixed to the shaft 18, by attachment in the aforedescribed manner, with the enlarged head 18a in overlying abuttment with that transverse end surface, not shown, of bar 20 which is opposite to the end surface 20a, whereby the overlain end of bar 20 is closed and the periphory of the head 18a extends slightly beyond the exterior flat walls of bar 20 for a purpose to be described. While the shaft 18 and bar 20 may comprise a common headed bolt and a length of square tubing, respectively, the equivalant of these elements may be formed as an integral piece if so desired.
Slideably carried on bar 20 are a front clamping sleeve 22 and a rear clamping and attaching sleeve 24. The sleeves 22, 24 are square tubular members with an interior dimension being somewhat greater than the exterior dimension of square bar 20, whereby only a limited degree of rotation of bar 20 relative to sleeves 22, 24 is possible. As shown in FIG. 2, the axial sliding movement of sleeve 22 and bar 20 relative to one another is limited in one direction by abuttment of the shaft head 18a and the extreme end surface 22a of sleeve 22.
A flat annular base or pressure foot 26 is fixedly attached, by welding or the like, to and in coaxial alignment with the rear end of sleeve 24. A flat face of the foot 26 abuts and partially closes the rear end of sleeve 24 which slopes with respect to the longitudinal centerline of the sleeve. This angle of attachment of the foot 26 and sleeve 24 of each mount establishes the angles B and C at which the mounts 10a and 10b project from the cabinet panel 12a. At its forward end, sleeve 24 surrounds a portion of the clamping bar 20 and opens toward the opposing open end of sleeve 22. The oppositely facing transverse end surfaces 22b and 24b, respectively, of sleeves 22 and 24 are spaced apart along the length of clamping bar 20 a distance denoted D in FIG. 2 when the reel 14 is fully clamped to mount 10a and the mount is firmly attached to panel 12a as will be more fully described.
As viewed in FIGS. 2 and 3, the long bottom wall 24a of sleeve 24 terminates at its forward end in a portion 24c deformed slightly downwardly to enlarge the opening of the sleeve in an outward radial direction. Such deformation of wall 24a provides a flared surface 24d which serves as a guide-in surface for one of the feet 14c of reel 14 which is received and clamped between the interior surface of wall 24a and the opposed exterior surface of the bottom wall 20b of the clamping bar 20. In the identical manner, the bottom wall 22c of the sleeve 22 is deformed to guide and receive the other reel foot 14c for clamping the same between the wall 22c and clamping bar wall 20b.
In a preferred installation of several mounts made in accordance with this invention, the cabinet 12 or an equivalant enclosure is employed to isolate the threaded shaft ends 18b within the interior space of the cabinet defined by the front panels 12a, spaced side panels 12d and top and back panel, not shown. The back panel may be opened for access to the back surface 12e of the front panel whereby, in a manner to be described, the shaft 18 can be removably attached to the front panel 12a. The bottom of the cabinet may be closed by a base, not shown, or may be closed by a floor surface on which the cabinet rests. Instead of a back closure panel or door, the cabinet may be positioned with respect to a wall or other upright surface so that the interior of the cabinet is not accessible to store customers.
Turning now to the means by which the mounts 10a, 10b are secured to the panel 12a, a fastener 28 threadably coacts with the rear end 18b of the shaft 18 to clamp a first washer 30, a spacer 32 and a second washer 34 in surrounding relation with shaft 18 between the fastener 28 and rear panel surface 12e. In the assembled relation shown in FIG. 2, the flat washer 30 bears against the wing nut 28 and, in turn, provides an annular bearing surface for the spacer 32 which comprises a hollow cylinder having a sloped annular end wall opposite washer 30. The flat washer 34 which is captured between the sloping spacer end wall and the rear panel surface 12e may conveniently have the same external and internal dimensions as the annular foot 26. The slope of the spacer wall is made the same as that of the sloped rear end wall of sleeve 24 to provide parallelism of the washer 34 and foot 26 to assure flush bearing engagement of the foot 26 and the washer 34 against the front and back panel surfaces, 12b and 12e respectively. The length of the spacer 32 is made great enough to prevent contact between the washers 30 and 34 when the nut 28 is fully tightened on shaft 18.
To provide sufficient strengh in the cabinet-mount combination to resist breaking of the cabinet or mount by a shoplifter, the cabinet panel 12a is made of plywood sufficiently thick to prevent tearing out of the front cabinet wall 12a about the foot 26; and, the bar 20 and sleeves 22 and 24 are square metal tubes having sufficient wall thickness to prevent manual bending or twisting off of the mount itself. The spacer 32 is conveniently and cheaply made from nonmetallic tubing and the members 30 and 34 as well as foot 26 may be common washers. For convenience in assembly the functions of the washers 30 and 34 and the spacer 32 could be combined in a one-piece member if desired.
Having disclosed in detail the structure of one preferred embodiment of the invention, the operation of the mount to secure it to the cabinet and to secure a reel to the mount will now be described.
With the parts of the mount completely disassembled from the cabinet panel 12a and from one another, the front clamping sleeve 22 is first positioned about the clamping bar 20 with transverse end surface 22a in abutting relation with the radially extending shaft head 18a. A reel of any selected type is then oriented with its forward end pointing toward the end 18b of the shaft 18. The reel mounting foot 14c which projects toward the head shaft 18a is then inserted into the lead-in opening between clamping bar wall 20b and the outwardly flared portion of sleeve wall 22c. Insertion of foot 14c between the bar 20 and sleeve 22 is limited in an axial direction by the wedging action of the tapered foot as it slides between the bar and sleeve. As an incident to penetration of the sleeve 22 by foot 14c, the sleeve and the bar 20 are urged radially toward one another until they are in surface-to-surface contact at a location opposite the foot 14c.
The rear clamping and attaching sleeve 24 is then positioned on the shaft 18 with the flared guide-in portion 24c opening toward its counterpart guide-in portion on the front clamping sleeve 22. The sleeve 24 is moved axially along the shaft 18 until the bar 20 and the underlying rear reel foot 14c are wedged within the forward end of sleeve 24, sustantially as shown in FIG. 2, with the upper surface of the bar urged into surface-to-surface contact with the upper wall of the rear sleeve 24, as viewed in FIG. 3.
With the reel display device assembled in the manner and to the extent described above, the threaded shaft 18 extends through the central aperture in the foot 26 and the reel 14 is located but not yet clamped on the shaft by the sleeves 22 and 24. The rear shaft end 18b is then inserted through the panel aperture 12c and beyond until the sloped surface of the pressure foot 26 is flush against the front panel surface 12b. From the rear of the panel, the washer 34, spacer 32, and washer 30 are assembled on the shaft 18 in that order; and, the wingnut 28 is actuated in the tightening direction causing the washer 30 to advance toward the back panel surface 12e. Before the nut 28 is fully tightened, the spacer 32 should be rotated about the shaft 18 so that its sloping end surface will bear against the washer 34 in such a manner as to tilt the latter about the shaft 18 for flush surface engagement with the back panel surface 12e, as best shown in FIG. 2. Continued actuation of the nut 28 after the washer 30, spacer 32 and washer 34 are aligned and compressed between the nut and the back panel surface 12e will axially move the shaft 18 rearwardly through aperture 12c causing the shaft head 18a to urge the front clamping sleeve 22 to override the tapered front reel foot 14c thereby firmly wedging it between the bar 20 and the sleeve 22. Likewise, the foot 26 of rear clamping sleeve 24 is pressed rearwardly against the front panel surface 12b due to frictioned engagement between the wedging surfaces of reel foot 14c, bar 20 and sleeve 24.
When the wingnut 28 is fully tightened, the pressure foot 26 and the washer 34 engage the panel 12a compressively therebetween to prevent either axial or rotory movement of the shaft 18 with respect to the panel; and, feet 14c of the reel 14 are respectively clamped between the bar 20 and the sleeves 22, 24; the angle B between the panel surface 12b and the centerline of mount 10a is established and maintained by the foot 26; and, the orientation of the reel 14 with respect to the mount 10a and the orientation of the mount with respect to the panel 12a will be maintained.
Although many of the benefits of this invention can be realized if the slope of the foot 26 of the clamping sleeve 24 is modified so that the shaft 18 always projects perpendicularily from the panel 12a, the opportunity afforded a customer to inspect and handle a reel is substantially enhanced if the angles B and C are 45°. To permit use of identically constructed mounts to carry spinning reels below a mount and casting reels above a mount, it is desirable that each mount be adapted for installation in either the angularly ascending attitude, according to mount 10a, or in the angularly depending attitude, according to mount 10b. However, when the mounts are to be displayed for customer inspection, the selection of angular attitude of a mount and selection of reel location on that mount is dictated by the real life location of the reel winding crank. Thus, for a spinning reel 14 the crank handle 14d is intended to be operated by the user's left hand; and, in the case of a casting reel 16 the crank handle 16d is operated by the user's right hand. Therefore, a spinning reel mount, 10a for example, projects upwardly at a 12 o'clock position with the pedestal feet 14c clamped below the clamping bar 20 while the casting reel mount, 10b for example, has the shaft 18 inverted through 180° so that its shaft 18 projects downwardly at the 6 o'clock position with the pedestal feet 16c clamped against the upper surface of clamping bar 20. While a mount constructed in accordance with this invention could be clamped to the panel 12a with the shaft 18 projecting at any desired clock location, the opposed 12 o'clock and 6 o'clock positions satisfy the requirements for displaying most types of fishing reels.
Once the mount is attached to a cabinet in the manner described above, the displayed reel may be removed or changed by loosening the wingnut 28 sufficiently so that the distance D, shown in FIG. 2, becomes great enough to permit the pedestal feet 14c to be disengaged from the clamping sleeves 22 and 24. Such disengagement can usually be accomplished without removal of wingnut 28 from the shaft 18 or disassembly of any other part from its position on the shaft 18. Should it be desired to use the illustrative spinning reel mount 10a to display instead a casting reel 16, the spinning reel is first removed in the manner just described; and, with the wingnut 28 loosened, the front end of the mount 10a is gyrated through a 180° arc to the 6 o'clock position as shown in the upper portion of FIG. 1. As an incident to such inversion of angular attitude, the rear sleeve 24 of mount 10 rotates 180° to maintain more or less flush contact between the foot 26 and the front panel surface 12b. Since the sleeves 22, 24 are nonrotatably linked by the bar 20, the front sleeve 22 will rotate with the rear sleeve 24 whereby both the aforedescribed lead-in portions of the sleeves will be located in the now inverted position at the upper surface of the rod 20. The substituted casting reel 16 may now be clamped to the inverted mount 10a by tightening the wingnut 28.
Another advantageous feature of this invention is that empty mounts may be stored in place on the panel 12a. In this storage mode, the wingnut 28 is tightened sufficiently to draw the transverse sleeve surfaces 22b and 24b into abutting contact and continued tightening of nut 28 causes the pressure foot 26 and washer 34 to engage the opposite surfaces of panel 12a as hereinbefore described.
While only two illustrative mounts are shown attached to the partial cabinet panel 12a, a multiplicity of identical mounts may be used to display a large variety of brands, sizes and types of reels on a cabinet front having a number of horizontally and vertically spaced rows of apertures 12c through which mounts are secured.
The foregoing description of a preferred embodiment of the invention is illustrative and explanatary only and various changes in the size, shape, and materials as well as in specific details of the illustrated construction may be made without departing from the scope and spirit of the invention. | A device for mounting fishing reels on a display panel comprising a shaft which penetrates the panel, sleeves moveably carried on the shaft and operable to clamp a reel to the shaft, and a fastener cooperable with the shaft to secure the device to the panel and to operate the reel clamping sleeves. | 0 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] Current methods for building and installing items such as wooden railings are time consuming and limited in effectiveness. Conventional connection methods, (e.g., toe-nailing; conversely, the use of screws at a 45% angle through one material into another) can fail on several counts. These methods lack strength, are often compromised structurally in a short time frame, and have glaringly visible nails or screws. Proposed installation method can be accomplished efficiently and expertly with relatively basic carpentry skills. Invention solves and eliminates the problem of marginally strong and unsightly connections by having fastener locked securely within materials, resulting in no visible fasteners as well as superior strength in the connection.
[0003] 2. Prior Art
[0004] Other recent approaches to installing items such as wooden railings have included the use of brackets or such like in order to overcome the failings of such older methods as toe-nailing. While many of these systems are marked improvements over said older methods, they are unattractive due to the visibility of both the brackets and the fasteners used.
PRIOR ART REFERENCES
[0005]
Patent#
Country
Date
4,688,769
USA
Aug. 25, 1987
4,792,122
USA
Dec. 20, 1988
4,899,991
USA
Feb. 13, 1990
5,474,279
USA
Dec. 12, 1995
6,290,214
USA
Sep. 18, 2001
6,527,469
USA
Mar. 4, 2003
6,557,831
USA
May 6, 2003
SUMMARY OF THE INVENTION
[0006] A system that includes a main fastener supplemented by a locking fastener, all parts of corrosion-proof materials such as any of the alloys known as “stainless steel”. Fasteners deployed in such a manner as to render them not visible to the end user of any assemblies thus secured.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0007] The fastening system shall consist of elements to fasten assemblies, typically to such vertical structures as a post or such like, said fastening elements to be hidden from common view after installation. Fastening elements shall be concealed typically by placement in a groove or channel let in to the body of the assembly. Fastening elements shall be corrosion-proof or otherwise secured against staining of: 1) the assemblies fastened, 2) the vertical structures, or 3) other materials in close proximity to said assemblies or said structures.
[0008] Fastening elements shall consist of both a Main Fastener and a Locking Fastener, installed as a single connection at each point where assemblies are to be joined to vertical structures.
[heading-0009] Main Fastener
[0010] A threaded fastener, typically a lag screw or such like, of a design which incorporates a hole at right angles to the main axis of the fastener. A typical configuration would be a 4″ lag-type screw with a flattened shank at the head, with a hole piercing the flattened area. The material shall be specified as corrosion-proof
[heading-0011] Locking Fastener
[0012] A fastener, typically a wood screw or such like, of a design which allows it to be easily driven through the pierced hole of the main fastener. A typical configuration would be a 1″ wood screw of a shank size such that same may readily secure the Main Fastener to the material to be secured. The material shall be specified as corrosion-proof.
[heading-0013] A Typical Groove in the Assembly to be Fastened
[0014] A groove, typically integral to the profile of a horizontal member of the assembly to be fastened. Other embodiments would include a groove cut, chiseled, routed or gouged into the end portion of said horizontal member; two channels in the profile of the horizontal member; such like structures as may be adapted to the purpose of accomodating the fasteners while allowing them to be concealed after installation.
DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 : An isometric drawing, depicting a typical main fastener 1 , with a typical locking fastener 2 in position to be engaged with 1 .
[0016] FIG. 2 : An exploded drawing, depicting a main fastener used as an upper fastener 3 , said fastener ready to be inserted into a typical post 4 . A second main fastener used as a lower fastener 5 , ready to be inserted into a typical post 4 .
[0017] FIG. 3 : A detailed isometric drawing, depicting a main fastener 6 , said fastener inserted into a typical post 7 , with a typical locking fastener 8 ready to be inserted through the hole in the head of said main fastener 6 . The locking fastener will be fastened into a typical upper assembly, as the upper rail 9 ; the main fastener 6 and the locking fastener 8 will both be hidden from view by the profile of said upper rail 9 .
[0018] FIG. 4 : A detailed isometric drawing, depicting a main fastener 10 , said fastener inserted into a typical post 11 , with a typical locking fastener 12 ready to be inserted through the hole in the head of said main fastener 10 . The locking fastener will be fastened into a typical lower assembly, as the lower rail 13 ; the main fastener 10 and the locking fastener 11 will both be hidden from view by the profile of said lower rail 13 .
[0019] FIG. 5 : An exploded isometric drawing, depicting a typical cap rail 14 positioned above fastener-and-upper rail assembly 15 .
CONCLUSION, RAMIFICATIONS, AND SCOPE
[0020] Stated method for processes such as railing attachments allows the use of fasteners such that they shall be hidden from view after installation. Concealing the fasteners maintains the high appearance values of carefully-crafted structures such as deck railings, stair railings, privacy screens, and such like.
[0021] Stated use of corrosion-proof fasteners maintains said high appearance values by preventing staining or other degradation of fine materials such as Western Redcedar, Coast Redwood, Oregon white Oak and such like due to harmful interaction of fastener material with these beautiful but acidic materials.
[0022] Preferred Embodiment states that Stainless Steel alloys such as ASTM 316 should be used for both the Main Fastener and the Locking Fastener. Use of this alloy or an equivalent imparts greater strength to the final installation, due to the ability of suchlike alloys to resist all natural corrosion such as that caused in a marine terrestrial environment.
[0023] Use of ASTM 316 for Main Fastener also increases durability of the connection due to the high tensile and shear strength of suchlike alloys relative to the more common steel formulations often used in prior fastening systems.
[0024] The combination of concealment of fasteners plus the use of corrosion-proof alloys assure that there will be no hazards presented to humans, domestic animals, fabrics or suchlike due to protrusions of fastener heads. In like manner, there will be no exposed wood fibers that have been torn by normal installation stresses (when assembly materials are of wood, this has been a common problem in prior art). | A fastening system, typically for wooden railings or such like, that includes a main fastener supplemented by a locking fastener, all parts of corrosion-proof materials such as any of the alloys known as “stainless steel”. Fasteners deployed in such a manner as to render them not visible after installation of items to be fastened. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a method of and apparatus for preparing a length of weft yarn for insertion into a shuttleless loom.
Known dispensing devices include a measuring device which draws the weft yarn from a stationary supply source and winds it on a drum so that the number of loops on the drum determines the measured length. Thereafter, the yarn is taken off the measuring drum and propelled through the warp shed. Experience has shown that there is a certain amount of surface tension between the yarn loops and the drum which must be overcome. With ever increasing loom speeds, it is important that the yarn is drawn into the warp shed with as little resistance as possible.
Other dispensing devices store a length of weft yarn in the form of a loop. This loop may be formed by a light spring or by blowing or drawing the weft yarn into a chamber. The disadvantage of this approach is that in outside filling supply looms, speeds are of such magnitude that the enertial stress on the weft yarn is extreme. The forces required to overcome the spring which holds the loop of weft yarn or to accelerate the loop of weft yarn will interfere with insertion of the weft yarn into the loom or may even result in rupture of the weft yarn.
It is a principal object of the invention to provide a method of and apparatus for yarn dispensing with less resistance than any known type of yarn measuring and dispensing devices and with less enertial stress to the weft yarn than prior art storage devices.
SUMMARY OF THE INVENTION
The principal object of the invention is accomplished by feeding weft yarn from a supply cone into a storage magazine wherein a helical air flow is created which directs the weft yarn into a helix or spatial spiral. The weft yarn is then withdrawn axially of the spiral for insertion into an outside filling supply loom. The magazine comprises a round hollow chamber within which is located a core which forms an annular space. The magazine also includes an inlet opening and an outlet opening. Weft yarn is introduced into the inlet opening and a helical air flow is created within the annular space which directs a length of the weft yarn into a helix or spatial spiral. This length of weft yarn is then withdrawn from the helix and directed through the outlet opening for insertion into the loom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general fragmentary plan view of the invention;
FIG. 2 is a side elevation of the preferred magazine embodiment;
FIG. 3 is a horizontal section taken along line 3--3 in FIG. 2 and looking in the direction of the arrows; and
FIG. 4 is a sectional view similar to FIG. 3, showing a modified magazine.
DETAILED DESCRIPTION OF THE INVENTION
Referring particularly to FIG. 1, the weft yarn preparing apparatus of the present invention is generally indicated by the reference numeral 10 and is shown diagrammatically in association with a loom indicated at 12, only a portion of which is shown. The loom may be of any type in which weft is inserted from outside supply packages as shown, for example, in my U.S. Pat. No. 3,412,763, dated Nov. 26, 1968. In this loom, weft yarn is inserted by means of a gripper projectile 7, which is pneumatically propelled across the loom from a launching device 8. However, this is an example of one type of loom for which the invention may be used.
Apparatus 10 comprises a storage magazine 14, and a weft measuring and feed device 16 which draws weft from a cone 18 and feeds it to the magazine 14. Associated with magazine 14 is a low pressure air source 20 and a high pressure air source 22. Low pressure souce 20 is connected to magazine 14 by an air line 24 for creating sub-atmospheric air pressure within the magazine in a manner to be described. High pressure source 22 is connected to magazine 14 by air lines 25, 26 and 27 for creating super-atmospheric pressure in the magazine in a manner also to be described.
Feed device 16 comprises a pair of feed rolls 28 and 30, at least one of which is positively driven by a shaft 32 driven in timed relation to the loom by interconnected drive means, not shown. Weft yarn will be drawn continuously from the cone 18 at the same rate that yarn is utilized by the loom.
Referring to FIGS. 2 and 3, magazine 14 is shown in greater detail and comprises a housing 34 having a chamber 36 which is circular in cross section, an inlet opening 37, and an outlet opening 38. A core 39 is located within chamber 36 and forms an annular space 40 with the wall 42 of the chamber. Chamber 36 comprises a central cylindrical portion 44, a first frusto-conical portion 46 connecting central portion 44 to inlet opening 37 and a second frusto-conical portion 47 connecting central portion 44 to outlet opening 38. Core 39 has a central cylindrical portion 48, a first frusto-conical portion 50 and a second frusto-conical portion 52. Core 39 is loosely located within chamber 36 and can be moved axially. When core 39 is moved toward the inlet opening, the first frusto-conical portion 50 will snugly engage the portion of wall 42 which forms the first frusto-conical portion 46 of chamber 36 and thereby effectively seals inlet opening 37 from the portion of annular space 40 around the central cylindrical part of the core 39. When core 39 is moved toward the outlet opening 38, second frusto-conical portion 52 will engage the portion of wall 42 which forms the second frusto-conical portion 46 of chamber 36 and thereby seals outlet opening 38 from the portion of annular space 40 around the central part of the core.
Core 39 is shifted toward outlet opening 38 by an actuator generally indicated by the reference numeral 54. Actuator 54 includes an outer ring 55, a middle ring 56 and an inner ring 57. Middle ring 56 comprises an annular outer portion 58 by which it is fixed to the housing 34 of magazine 14, an annular central horizontal portion 59 and an inner annular lip portion 60. Inner ring 57 is generally located within ring 56 and comprises a first annular projection 62 which extends beyond the inner end of middle ring 56 and outwardly from the central longitudinal axis X of the magazine beyond portions 59 and 60 of the middle ring 56. Ring 57 also comprises a second annular projection 64 which abuts the inner surface of the central portion 59 of the middle ring, and an intermediate portion 66 which connects the first and second annular projections. Portion 66 also forms the second frusto-conical portion 46 of the chamber 36. Outer ring 55 is slidably mounted on the outside of central portion 59 along the axis X and is confined between projection 62 of the inner ring and outer portion 58 of the middle ring. An annular space 68 is formed between outer ring 55 and portion 58 of the middle ring. A spring 69 extends between projection 64 and lip 60 to maintain projection 62 against lip 60. A port 70 is alligned with space 68 and is pneumatically connected with high pressure source 22 through air line 27. A valve 72 is located in line 27 and is opened and closed by a cam 74 driven by a shaft 76 which in turn is driven in timed relation with the loom by interconnected drive means, not shown. At the proper time in the loom cycle, cam 74 opens valve 72 so that air at super-atmospheric pressure enters space 68 and drives outer ring 55 inwardly to the left as viewed in FIG. 3. Since outer ring 55 bears against projection 62, inner ring 57 is also driven inwardly against the action of spring 69 to push core 39 to the left to the position it occupies in FIG. 3. When core 39 is moved to the right by means to be described, valve 72 is again closed so that actuator 54 will engage portion 50 of the core just prior to its movement to the right. Just as core 39 begins to move to the right as viewed in FIG. 3, valve 72 will be closed. Valve 72 is a three way valve which dumps the pressurized air between the valve and actuator 54 when the valve is closed. Spring 69 will return inner ring 66 to its original position. This dumping can be instantaneous or slow so that the movement of actuator 54 to the right, as viewed in FIG. 3, will match the movement of the core 39 in that direction. In this way, inner ring 66 will act as a guide for the core and maintain it in allignment along axis X, so that space 40 will be uniform and core 39 will not strike wall 42.
The means for creating an air flow from inlet opening 37 into space 40 comprises an exhaust port 78 in housing 34 which is pneumatically connected to space 40. Port 78 is pneumatically connected to low pressure source 20 by air line 24. A valve 80 is located in line 24 and is opened and closed by a cam 82, which is driven by a shaft 84, driven in timed relaton with the loom by interconnected drive means, not shown. When valve 80 is opened by cam 82, air is drawn from the magazine by source 20, so that sub-atmospheric pressure is created at the port 78. The effect of this sub-atmospheric pressure draws air through space 40 from inlet opening 37.
The means for making the air flow within space 40 helical, comprises a ring 86 which forms the wall of the central cylindrical portion of chamber 36. A series of spaced turbine blades 87 are annularly arranged on the outside of ring 86 and are alligned with a port 88 which is pneumatically connected by air line 25 to high pressure source 22. Air at super atmospheric pressure from source 22 is directed against turbine blades 87 to cause ring 86 to rotate around axis X. The rotation of ring 86 will cause the air passing from inlet opening 37 to port 78 to flow helically. Weft yarn, indicated by the reference numeral Y, is fed to inlet opening 37 from feed device 16 and is drawn into the space 40 by the helical air flow therein. Weft yarn drawn into space 40 is deposited on the portion 48 of core 39 in the form of a helix or spatial spiral. A porous graphite bearing ring 90 is mounted between ring 86 and the outer wall 92 of housing 34. Air at super-atmospheric pressure is introduced through a port 94 which is pneumatically connected to bearing ring 90. Pressurized air is supplied to port 94 from air line 25 and permeates bearing 90 to decrease the fricton between ring 86 and bearing 90 and enables ring 86 to rotate with very little frictional resistance.
The means for withdrawing the weft helically deposited on core 39 comprises a port 96 located adjacent outlet opening 38 and the end of second frusto-conical portion 52. Port 96 pneumatically connects chamber 36 to high pressure source 22 by means of air line 26. A valve 98 is located in line 26 and, upon being opened, allows air at super-atmospheric pressure to enter port 96 from source 22. Valve 98 is opened and closed by a cam 102 mounted on a shaft 104 which is rotated in timed relation with the loom in the same manner as shafts 76 and 84. At the proper time during the loom cycle, valve 98 is opened and valves 80 and 72 are closed so that chamber 36 is pressurized from port 96. This forces core 39 to the right as viewed in FIG. 3 and causes portion 50 of the core to seat within portion 46 of the chamber and seal inlet opening 37 from space 40. At the same time, the seal between portion 52 of the core and the portion of wall 42 which defines portion 47 of the chamber, is broken. Since valve 80 is closed and opening 37 sealed, the pressurized air within chamber 36 will escape through outlet opening 38. The helically wound yarn on core 39 will be drawn out through opening 38 axially of the core by this air flow. This discharge of weft yarn from the magazine will be effective to insert the weft into the warp shed or to assist the insertion of weft therein by a projectile such as projectile 7 shown in FIG. 1. This length of weft yarn will be drawn from the helix with extremely little resistance.
The valves 72, 80 and 98 are timed so that core 39 is reciprocated within chamber 36 once for each weft insertion. Valve 72 is open long enough to enable enough weft yarn to be wound on core 39 for one weft insertion. Valve 98 is opened and valves 72 and 80 are closed to allow core 39 to be shifted to the right as viewed in FIG. 3, just prior to weft insertion into the warp shed of the loom.
Referring to FIG. 4, there is shown a modified magazine 106 which comprises a housing 34' which contains a chamber 36' and core 39'. Chamber 36' and core 39' are identical to chamber 36 and core 39, respectively. Housing 34' has an inlet opening 37' and an outlet opening 38'. The mechanisms for shifting core 39' along the central longitudinal axis X' of the housing are identical to those of the magazine shown in FIG. 4 and identical elements have the same reference numerals, except that the elements in magazine 106 are suffixed with a prime. Magazine 106 differs from magazine 14 by the means for creating a helical airflow in the space 40' between the central part of core 39' and the wall 42' of the chamber 36'. The means for creating a helical airflow within space 40' comprises a ring 108 which forms the central portion 44' of the chamber 39'. Ring 108 is mounted for rotation around axis X' within bearings 110. This rotation causes air passing through space 40' to flow helically in the same manner as ring 86. Ring 108 is rotated by means of a belt 112 which drivingly engages a sheave 114 fixed to the outside of ring 108. Belt 112 is driven by conventional drive means, not shown. An exhaust port 78' in housing 34' is pneumatically connected to space 40' by an annular channel 116. Air line 24' is connected to a low pressure source for creating sub-atmospheric air pressure in port 78' in the same manner as in the first embodiment, except that there is no valve in line 24'. Instead, there is an annular expandable resilient tube 118 which lies partially within channel 116 which is effective when expanded to completely block channel 116 and thereby prevent air from passing from space 40' to port 78'. Tube 118 is pneumatically connected to a high pressure source 120 by an air line 122. A valve 124 is located in air line 122 and is opened and closed by a cam 126 fixed to a shaft 128 which is driven in timed relation to the loom by interconnecting drive means, not shown. The opening and closing of valve 124 is such that tube 118 will be deflated during the period of time that weft yarn is being deposited on core 39' and inflated when weft yarn is being withdrawn from the magazine to the loom. | Method of and apparatus for preparing a length of weft yarn in a magazine for insertion in a shuttleless loom. Weft yarn is drawn from a supply package into a storage magazine wherein a helical airflow is created which directs the weft yarn into a helix from which the weft yarn is then withdrawn axially of the helix for insertion into the loom. | 3 |
TECHNICAL FIELD
[0001] The present invention is generally directed to a device for loading a kayak or similar object onto a vehicle. More particularly, the present invention is directed to a device which is employed in conjunction with well-known car roof-mount systems. The present invention is used with such systems to raise a kayak from ground level to a height consistent with its placement on/in the roof mount. The present invention may also be employed with roof rack systems comprising two bars/rods extending from one side window of a vehicle to another.
BACKGROUND OF THE INVENTION
[0002] The present invention is designed for use by kayakers and the users of small boats having weights and structures similar to those of a kayak. While kayaks are generally considered to be relatively lightweight in comparison to other boats, nonetheless they are typically transported by means of roof racks on a vehicle. There are several brands of roof rack that are typically employed in the transport of kayaks, these include the following two widely used brands: Thule® and Yakima®. The roof racks provided by these manufacturers and by others for the purpose of transporting various objects typically include at least two support structures that extend from one side window of the vehicle to the opposite side window. These two support structures are typically disposed in a parallel relation so as to support a kayak on the roof of the vehicle. Naturally, the kayak is oriented so that its prow is pointing to the front of the vehicle and its stern is pointing to the rear of the vehicle. Clearly, this orientation may also be reversed.
[0003] Manufacturers supply basic roof racks and additional attachments for loading various objects on a vehicle. For example, the basic roof rack structure may include an attachment for holding one or more bicycles on the roof of the vehicle. Similarly, the basic roof rack structure may also include an extra cargo pod for holding suitcases, sporting equipment, and the like for long trips. Most relevantly for the present invention, however, the two cited manufacturers, and others, also supply attachable cradles for holding kayaks. In general, kayaks are affixed to vehicles in one of two positions: (1) flat or down; and (2) at an angle in a cradle. This latter positioning is particularly advantageous when it is desired to carry a number of kayaks on the same vehicle at the same time. It is this last cradling arrangement which is taken advantage of in a preferred embodiment of the present invention. It is noted, however, that the present invention is also employable using a basic roof rack structure not having additional cradles for a boat.
[0004] Cradling structures for holding kayaks on a roof rack are illustrated in US patent application number US 2014/0263503 published on Sep. 18, 2014 in the name of Laverack et al.
[0005] It is also known that it is possible to employ rods extending from the ends of the roof rack to the ground in a sloped configuration. Such a device is illustrated in FIG. 4 , discussed more fully below, and may be used in conjunction with the present invention but is not part of the present invention.
[0006] Individuals who are older, disabled, suffer from muscle or joint weakness or who are afflicted with various illnesses may not always be in a condition to lift a kayak to the full height of a vehicle roof. This is particularly true if the vehicle is a van rather than a sedan. Such individuals may require, perhaps only from time to time, a convenient mechanism for moving the kayak from ground level to vehicle roof level; and, correspondingly, from the roof level back to the ground. Such a mechanism should be lightweight, easy to handle, easy to install. It is also convenient if the mechanism is easily foldable until it is needed.
[0007] From the above, it is therefore seen that there exists a need in the art to overcome the deficiencies and limitations described herein and above.
SUMMARY OF THE INVENTION
[0008] The shortcomings of the prior art are overcome and additional advantages are provided through a series of four connected support rods that are affixable to a basic roof rack. The device includes a first horizontal support which is affixable to both parts of a standard roof rack. A second horizontal support is also affixable to both parts of the roof rack; these first two supports lie substantially in a single plane. A third support is rotatably connected, substantially at a right angle to the first support. Typically the third support extends upwardly at an angle and toward one side of the vehicle. The third support also includes a hoist at the other end for lifting the kayak. A fourth support connects the second horizontal support and the third support, the connection between the fourth support and the third support is slidable along the third support, with said fourth support being rotatably connected with the second horizontal support. The fourth support serves to hold the third support in an upwardly angled position with the end of the third support being disposed substantially above the side of the vehicle adjacent to the kayak on the ground to be loaded.
[0009] In an alternative embodiment of the present invention, the second support is affixed to the top of a cradle structure used to hold a kayak. These cradle structures are in common use. In fact, in various embodiments of the present invention the second support structure (rod/bar) is a fixable to any part of a vertical portion of the kayak cradle.
[0010] In yet another embodiment of the present invention, instead of being affixed to the roof rack itself, the second (horizontal) support is affixed to the vertical portion of a kayak cradle which is itself affixed to the roof rack structure. Lengths of the supports in this embodiment are adjusted so that in its final configuration the waste portion referred to above is positioned substantially over the edge of the vehicle roof. This is particularly true of the third support
[0011] Furthermore, in order to cut down on vibration due to wind conditions when driving, guy wires may be employed connecting the third support to the second support. The device of the present invention is affixed to the roof rack by any convenient conventional means. This includes ropes and records, cleave this pin structures, nuts and bolts, screws and even an adhesive although this is not recommended. In preferred uses of the present invention the apparatus is affixed to the roof rack by means of nylon strips together with any number of possible cinching devices.
[0012] Accordingly, it is an object of the present invention to provide a portable device for lifting a kayak to the roof of a car.
[0013] It is another object of the present invention to provide a device which assists physically limited individuals in the lifting of an object such as a kayak.
[0014] It is yet another object of the present invention to provide a device which is easily construct a ball and which is portable.
[0015] It is a still further object of the present invention to provide a lifting device which is lightweight and easy to attach to a standard roof rack.
[0016] It is still another object of the present invention to provide a kayak lifting device which is usable with a roof rack and kayak cradle to enable the lifting of the kayak into the cradle.
[0017] Lastly, but not limited hereto, it is an even further object of the present invention to provide a kayak lifting device which is easily manufactured and assembled on-site.
[0018] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention.
[0019] The recitation herein of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
[0021] FIG. 1 is a front, elevation view illustrating the components of the invention;
[0022] FIG. 2 is a side, elevation view illustrating the same structure as show in FIG. 1 ;
[0023] FIG. 3 is a side elevation view similar to FIG. 3 but more particularly illustrating an embodiment of the present invention that does not require a kayak cradle;
[0024] FIG. 4 is an overhead view illustrating an initial phase of the use of the present invention in loading a kayak on a vehicle;
[0025] FIG. 5 is an angled, front view of the present invention installed on a vehicle;
[0026] FIG. 6 is a view similar to FIG. 4 except shown from a rearward position;
[0027] FIG. 7 is a view illustrating the use of a supplemental loading support rod which is placed within the kayak seat opening to facilitate lifting;
[0028] FIG. 8 is a view of the present invention shown in a collapsed or folded configuration; and
[0029] FIG. 9 is a view illustrating the final positioning of a kayak in a roof rack, as positioned by use of the present invention.
DETAILED DESCRIPTION
[0030] FIG. 1 illustrates a view of the present invention as seen by an individual standing next to a kayak about to be loaded onto the vehicle. In particular, there is shown a first horizontal support 102 together with a T-shaped connector 110 into which the end of (third) support 108 is inserted. Connector 110 comprises a standard T-shaped pipe connector having a diameter and/or a cross-section into which supports 102 and 108 are inserted. Support 102 is intended to be easily slidable within connector 110 . This is provided for ease of assembly and transport but is not an essential feature of the present invention. Support 108 is preferably pivotable in the sense that support 102 exists in the form of an axis of rotation. This rotatability is provided by connector 110 . Similar features of rotatability and slidability are preferably provided by the other connectors shown in FIG. 1 namely connectors 112 and 114 .
[0031] Support 108 , in utilization, is intended to be angled upward from the roof of the car on a side thereof positioned distally from support 102 so that its end is positioned substantially over the edge of the roof nearest the boat which is intended to be lifted. Although not shown in FIG. 1 , the distal end of support 108 has attached thereto a hoist which is described elsewhere herein. This hoist is visible in FIG. 9 .
[0032] Support 108 is in turn connected to support 106 by means of connector 114 . Support 106 is similarly connected to (second) support arm 102 by means of connector 112 . Support 102 may be affixed to different structures depending upon the particular embodiment of the present invention. In the most general embodiment, support 102 is affixed to the roof rack by any convenient means but preferably by means of cinchable nylon straps. In embodiments of the present invention in which it is used in conjunction with a kayak cradle, support 102 is affixed to a vertical portion of the cradle, typically at the top of the vertical cradle portion.
[0033] In preferred embodiments of the present invention the connectors are intended to have a circular cross-section for purposes of rotatability. However, in those embodiments of the present invention in which it is transported as a single unit, circular cross-sections are not required.
[0034] Attention is next directed to the structure illustrated in FIG. 2 . The apparatus shown here is the same one as shown in FIG. 1 . However, it is a view seen by an individual standing at the front or rear of the vehicle. This view is helpful in understanding the issues of rotatability and slidability. Again, it is noted that these features are important for providing portability, transportability and ease of assembly on-site. In the most general embodiment of the present invention, the subject apparatus forms a solid, more unitary structure wherein these features are not essential. FIG. 2 is also useful in understanding the role played by (fourth) support 106 . The length of support 106 determines the angle that support 108 makes with support 102 .
[0035] FIG. 3 is a view of the present invention similar to the one shown in FIG. 1 with the exception that supports 102 and 104 are substantially at the same height reflecting the fact that, in this embodiment, these supports are affixed directly to the roof rack instead of to the vertical portions of a kayak cradle.
[0036] FIG. 4 is an illustration of the use of the present invention in conjunction with what is probably best described as “ramp rods.” As mentioned above, such devices are known in the art and provide somewhat of a mechanical advantage in terms of lifting a boat to roof height. This view also illustrates the relationship between the present invention, a vehicle, its standard roof rack, kayak cradles, “ramp rods” and a kayak.
[0037] FIG. 5 is a more detailed illustration of the utilization of kayak cradles. These cradles are shown being used in conjunction with the present invention. In particular, it is seen in this figure that supports 102 , 104 , 106 and 108 are specifically referred to.
[0038] FIG. 6 is particularly illustrative of the fact that nylon straps may be employed connecting supports 102 and 104 . As above, these are cinchable straps. They are employed to provide additional overall structural rigidity and to reduce vibration due to vehicular speed during transport. Also shown in FIG. 6 is the presence of guy wires extending substantially from connector 114 two ends of support 102 .
[0039] FIG. 7 is particularly important in that it illustrates a preferred mechanism for connecting the hoisting cable (wire, rope, cord, chain, etc.) to the kayak. A typical kayak possesses a cockpit opening into which horizontal bar 115 is placed. Clearly, bar 115 is selected to be longer than the opening of the kayak cockpit. A cable connects this bar to the hoisting mechanism and it is this bar which carries the weight of the kayak as it is lifted. Bar 115 comprises any convenient material.
[0040] FIG. 8 is relevant in that it illustrates the present invention in a folded configuration.
[0041] FIG. 9 is relevant in that it illustrates the presence of a kayak sitting in a cradle after has been lifted into place using the present invention.
[0042] The supports referred to in the present invention may comprise rods or bars having any desirable cross-section. In preferred embodiments of the present invention the supports referred to herein comprise lightweight aluminum tubes. They may be of any convenient length or diameter. Such tubes are lightweight and render fabrication easy. The couplings between support structures in the present invention preferably comprise T-shaped plastic piping comprising material such as PVC. These materials are lightweight easy to assemble and are not particularly sensitive to exposure to water. In the event that the kayak is a sea kayak intended for salt water use specially graded aluminum is preferably employed. While aluminum is preferred for the support structures of the present invention, it is also possible to employ wood, steel or plastic. The support structures do not have to each comprise the same material.
[0043] It is to be noted that, as used herein, the term “hoist” is intended to refer to any device having a mechanical lifting advantage. In typical embodiments of the present invention the hoist comprises a conventional arrangement of pulleys. In other embodiments of the present invention it is also possible to employ ratcheting devices such as “come-alongs.” The present invention may also be fitted with a battery-powered winching device.
[0044] All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
[0045] Although the description above contains many specifics, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 USC §112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
[0046] While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the spirit and scope of the invention. | A device for loading a kayak onto a vehicle comprises four connected supporting arms. The first and third arms are connected at substantially right angles. A second arm is connected via a fourth arm to the third arm. The connections are made at right angles through T-shaped connectors which provide rotatably and slidability. | 1 |
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for optimizing and controlling the metallurgical properties of an alloy during a homogenization process by predicting the degree of transformation of an alloy during homogenization.
[0003] 2. Description of Related Art
[0004] Aluminum alloys are typically homogenized after casting. The purpose of the homogenization process is to:
1. Dissolve precipitation hardening phases that are segregated during the casting process to optimize the final metallurgical properties of the material. 2. Transform insoluble phases into preferred phases that facilitate downstream working operations (such as extrusion or rolling). 3. Precipitate the dispersoid phases that are in solid state solution from the casting process to the proper size and distribution to optimize the final metallurgical properties of the material.
[0008] The homogenization process for aluminum alloys has been controlled historically by heating the subject material to a set temperature range (soak temperature) and holding that material for a designated time (soak time). This method of control assumes either a consistent heating rate of the material or ignores the amount of transformation that occurs during the heat-up completely. This historical method of control is depicted graphically in FIGS. 1-3 . FIG. 1 depicts the hypothetical limits for the metallurgical transformations described above. FIG. 2 depicts the historical control goals which assume isothermal conditions throughout the soak. FIG. 3 depicts the more realistic control goals with dynamic temperature and time conditions.
[0009] The historical method of control results in inconsistent material properties after homogenization as a result of failing to account for the portion of the metallurgical reaction that occurs during the heat-up portion of the cycle and the variation within that batch that potentially occurs. Larger batch sizes, with slower heating rates, have greater temperature exposure than smaller batches with faster heating rates and the same soak time and temperature. In addition to this, variation in temperature throughout a batch makes it difficult to assure that the coldest part of the batch received enough time at temperature for the desired metallurgical reactions to occur, while the hottest part of the batch may receive too much time at temperature, resulting in coarsening of the dispersoid phases. This is depicted in the differences between FIGS. 2 and 3 , where temperature is shown as being dynamic and represented by a control range that was achieved at different times at various positions throughout the load.
BRIEF SUMMARY OF THE INVENTION
[0010] One aspect of the present invention is to provide a method for optimizing and controlling the homogenization of an alloy in a furnace. The method includes defining a target degree of transformation to achieve at least one metallurgical property for the alloy. The desired metallurgical properties include, but are not limited to, dissolving precipitation hardening phases, transforming insoluble phases into preferred phases and precipitating the dispersoid phases to the proper size and distribution. Using regression analysis, a transformation model is obtained to predict the degree of transformation of an alloy by analyzing the degree of transformation of a plurality of sample alloys subjected to heating at predetermine temperatures for predetermined amounts of time. The homogenization process is controlled and optimized by monitoring the temperature of the alloy at incremental time periods through-out the heat-up and soaking portion of the homogenization process to incrementally calculate the degree of metallurgical transformation using the transformation model. Each incremental calculation of the degree of metallurgical transformation is recorded to achieve a total amount of metallurgical transformation. Using the transformation model, the total amount of time in the furnace is calculated to achieve the target degree of transformation.
[0011] This homogenization integration process assures that the target metallurgical reactions and properties are met consistently throughout the homogenization load, within the capabilities of the furnace. By controlling the homogenization process via homogenization integration, the metallurgical properties of the material relative to mechanical properties (including, but not limited to: yield strength, ultimate strength, elongation, fracture toughness and fatigue life); workability in downstream operations (including, but not limited to: extrusion, forging and rolling); and improved surface finish of the final product after working are optimized to the target levels desired for the end use application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The features and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, in which:
[0013] FIG. 1 depicts the hypothetical limits for the metallurgical transformations using historical controls;
[0014] FIG. 2 depicts the historical control goals which assume isothermal conditions throughout the soak;
[0015] FIG. 3 depicts the more realistic control goals with dynamic temperature and time conditions using historical controls;
[0016] FIG. 4 is a graph showing the representative time/temperature study for development of the homogenization integration model according to the present invention;
[0017] FIG. 5 is a graph showing Parameter A (% transformation/s) as a function of temperature using the homogenization integration model according to the present invention;
[0018] FIG. 6 is a graph showing the transformation rate relative to degree of transformation using the homogenization integration model according to the present invention; and
[0019] FIG. 7 are pictures showing the metallographic examination of ingot with lab homogenization, ingot with homogenization integration cycle, and ingot with standard homogenization.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention is directed to a method for optimizing and controlling the homogenization process used for an alloy, such as an as-cast alloy, prior to further processing operations. This is accomplished by characterizing the metallurgical properties of the homogenized alloy in terms of the total degree of metallurgical transformation. As-cast samples of the alloy are heated at various temperatures with relatively fast heating rates, held for a finite period of time, and water quenched to stop any further metallurgical reaction (thus eliminating any cooling rate effects). The degree of metallurgical transformation of each sample is then determined via standard laboratory techniques, such as differential scanning calorimetry, metallographic examination and scanning electron microscopy. This provides isothermal curves relating degree of metallurgical transformation to time at a given temperature as shown in FIG. 4 .
[0021] This data is then converted into a transformation model as a function of time for a set temperature based on the best curve fit. Preferably, the transformation model is set up using an exponential regression method with data from a plurality of samples of the alloy with associated degrees of metallurgical transformation at a given time and a given temperature. Assuming an exponential relationship, this gives the following equation:
[0000] ω= e −At
[0000] where: ω=percent transformation; A=temperature specific fitting parameter (unit is s −1 ); t=time (in seconds).
[0022] Continuing to assume an exponential relationship, A is calculated for each temperature with results as shown in FIG. 5 . Using this information, the actual amount of phases left untransformed (ψ—or degree of metallurgical transformation) can be determined by the following formula:
[0000] ψ=1−ω
[0000] or
[0000] ω=1 −e −At
[0000] The rate of metallurgical transformation must be determined as a function of time. This can then be integrated over time to predict the degree of metallurgical transformation. If integrated over long periods of time, this relationship is destroyed, as a result of the dynamic nature of temperature throughout the cycle affecting the metallurgical transformation rate. Therefore, rather than expressing the metallurgical transformation rate as a function of time, it is converted into a function of degree of metallurgical transformation as shown below.
[0000] ψ=1 −e −At
[0000] ψ′= dψ/dt
[0000] ψ′= A e −At
[0000] ψ= A (1−ψ)
[0023] Plotting the metallurgical transformation rate (ψ′) relative to the degree of metallurgical transformation (ψ), gives the relationship shown in FIG. 6 .
[0024] Since the metallurgical transformation rate is dependant on A for a given temperature, the results from FIG. 5 are used to determine A for a given temperature.
[0025] The transformation model is then complete with the following equations:
[0000]
A=Be
CT
[0000] ψ′= A (1−ψ)
[0000] ψ′= Be CT (1−ψ)
[0000] where: ψ=degree of metallurgical transformation; ψ′=metallurgical transformation rate; A=temperature specific fitting parameter; t=time, B and C are alloy dependent constants for the exponential relationship of A relative to temperature (T).
[0026] The metallurgical transformation rate can then be solved by using either a predicted or measured temperature for an incremental time period and determining the transformation rate for this incremental time period as a function of the accumulated degree of transformation up to that point in the cycle. This results in a new degree of transformation that is continuously monitored as a control parameter and used in the next calculation for phase transformation rate.
[0027] In one embodiment, the method for optimizing the homogenization process uses a computer program embodied on a computer readable medium (also referred to herein as homogenization integration control software) for optimizing the homogenization process of an alloy in which the alloy is produced from an input stock where production conditions are detected on-line throughout the entire homogenization process, wherein the metallurgical properties to be expected of the alloy are calculated in advance. It is understood by those of skill in the art that the time and temperature of an alloy in an homogenization process may be recorded using a variety of known devices. For example, in practice, a load thermocouple would be used as an input into the homogenization integration control software. The calculation per the above formulas would then be used to determine the incremental degree of metallurgical transformation and this would be added to the accumulated metallurgical transformation established from the start of the cycle. An alternative method of control would be to use an air thermocouple to monitor the furnace cycle, and use an established relationship between the air and load temperatures to predict the load temperature. This information would then be used as in input into the homogenization integration control software to determine the desired degree of metallurgical transformation for an incremental portion of the cycle. The software then tracks the total degree of metallurgical transformation and determines the amount of time in the furnace based on metallurgical transformation, rather than a time at a given temperature. This process of controlling and optimizing the homogenization process of an alloy using the above-defined transformation model is also referred to herein as “homogenization integration control”.
[0028] The transformation model accurately provides a quantitative predictor of the degree of transformation in an alloy as a function of time and temperature both during heat-up and soaking regardless of the batch size. The present transformation model provides a means to predict the degree of transformation necessary to obtain an alloy with desirable properties. More particularly, the transformation model of the present invention can be applied to quantitatively predict the degree of transformation in aluminum alloys. By way of example, the application of the transformation model to a 6061 aluminum alloy homogenization process is described below. It is to be understood though that the transformation model of the current invention can be applied to any alloy composition.
[0029] This method of control provides significant productivity gains in the homogenization cycle itself, but also provides greater consistency in the homogenized product. This consistency allows downstream operations (including, but limited to extrusion, rolling and forging) to also be optimized, rather than planning for the worst case homogenized structure, as has been done historically with conventional control methods. This results in significant productivity gains in these processes as well.
EXAMPLES
[0030] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and/or methods described and claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight and pressure is at or near atmospheric. There are numerous variations and combinations of conditions, e.g., alloy composition, temperatures, pressures and other ranges and conditions that can be used to optimize the methods described herein. Only reasonable and routine experimentation will be required to optimize such process conditions.
Example 1
[0031] An as-cast sample of aluminum alloy 6061 was homogenized at 1050° F. for four hours in a lab furnace to assure 100% Fe transformation from β to α and 100% transformation of Mg 2 Si from undissolved to dissolved phases. Similar samples of 6061 were homogenized in production furnaces—one using homogenization integration control targeting 100% transformation of both Fe and Mg 2 Si and the other using a typical time and temperature soak control. The results of all three samples were evaluated via DSC to determine degree of Fe and Mg 2 Si transformation. The results are shown in Table 1. The samples were also evaluated metallographically with the results shown in FIG. 7 . FIG. 7 shows the transformations of a 6061 alloy. Note that all of the Mg 2 Si is dissolved relative to the as-cast structure. Also note that the Fe phases are transformed from continuous, sharp sickle shaped phases to rounded spheroidal shapes (indicating the metallurgical transformation of the insoluble phases).
[0000] TABLE 1 DSC Analysis of Lab versus Production Homogenization Integration Transformations Produc- Lab Production Lab β tion β Dissolve Dissolve to α Fe to α Fe Mg 2 Si Mg 2 Si Energy Required for Further 0 J/g 0 J/g 0 J/g 0 J/g Transformation Lab vs. Production Homogenization Integration Energy Required for Further 0 J/g 0.28 J/g 0 J/g 3.24 J/g Transformation Lab vs. Typically Controlled Production Furnace
The typically controlled production furnace results indicate that the Fe transformation was 38% complete, while the Mg 2 Si was 40% complete relative to the desired. This is compared to the homogenization integration controlled cycle that achieved 100% transformation.
[0032] The Mg 2 Si being completely dissolved in aluminum 6XXX alloys is beneficial especially for products that planned to be quenched from hot working operations as a solution heat treatment (i.e. extrusion). This provides greater consistency in mechanical properties as well as limits the potential for isolated melting of the Mg 2 Si (incipient melting) during the hot working operation, which results in hot shortness surface cracking and is typically overcome by reducing extrusion speeds, and thus productivity. The Fe transformation also significantly improves potential extrusion speeds. The long, sickle shaped Fe phases, as shown in the as-cast and conventional homogenization controlled cycle tear the surface of the metal as it is being hot worked, particularly during extrusion. The degree of surface tearing is proportional to the strain rate, and thus this condition is also typically corrected by slowing the hot working speeds, and thus productivity.
Example 2
[0033] A conventional soak temperature and time strategy was developed for a furnace to assure all target metallurgical transformations were achieved. The average cycle time was recorded for this process and determined to be 520 minutes. The homogenization integration control was then implemented on this same furnace and the average cycle time for the same product was determined to be 447 minutes. Both cycles achieved equivalent transformations, but the homogenization integration control provided greater target consistency and achieved a 14% improvement relative to the original control strategy. The reason for this difference in productivity was the control method had to assume the slowest potential heat-up rate for the material to ensure full metallurgical transformation. Since the homogenization integration control system accounts for the metallurgical transformation during the heat-up rate, material that receives faster heat-up rates can be held at soak temperatures for shorter periods of time. Despite the variation in soak times, the product is controlled to a target degree of metallurgical transformation and thus the consistency of the product is dramatically improved.
Example 3
[0034] Production samples of aluminum billet were homogenized using a furnace with homogenization integration control were extruded and compared with billets of the same alloy homogenized on a different furnace for approximately the same cycle time and target temperature without homogenization integration control (conventional control). The differences in microstructure are shown in FIG. 7 . The billet was used to extrude over 20 different shapes. The extrusion rates of these 20 shapes were 15-25% faster with the homogenization integration controlled billet as compared to the conventionally controlled billet. Not only were the extrusion rates significantly greater, but the surface quality of the extrusion also improved significantly.
Example 4
[0035] The surface roughness of extrusions made from billets homogenized using conventional control techniques were compared to extrusions made from billets using homogenization integration control. The average surface roughness of the extrusions from conventionally controlled homogenized billet was 94.9 Ra, while the average surface roughness of the extrusions from homogenization integration controlled billets resulted in a surface roughness of 33.3 Ra. The observations from each location spanned 20 production orders from each billet condition.
[0036] Although the present invention has been disclosed in terms of a preferred embodiment, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention as defined by the following claims: | The homogenization cycle of an alloy is optimized and controlled by defining a target degree of transformation to achieve at least one metallurgical property for an alloy. The desired metallurgical properties include, but are not limited to, dissolving precipitation hardening phases, transforming insoluble phases into preferred phases and precipitating the dispersoid phases to the proper size and distribution. Using regression analysis, a transformation model is obtained to predict the degree of transformation of an alloy by analyzing the degree of transformation of a plurality of sample alloys subjected to heating at predetermine temperatures for predetermined amounts of time. | 2 |
FIELD OF THE INVENTION
This invention relates in general to field effect transistors and more specifically to vertical field effect transistors.
BACKGROUND OF THE INVENTION
Field effect transistors (FET's) are a fundamental building block in the field of integrated circuits. FET's can be classified into two basic structural types: horizontal and vertical. Horizontal, or lateral, FET's exhibit carrier flow from source to drain in a direction parallel (e.g. horizontal) to the plane of the substrate on which they are formed. Vertical FET's exhibit carrier flow from source to drain in a direction transverse to the plane of the substrate (e.g. vertical) on which they are formed.
While horizontal FET's are widely used and favored in the semiconductor industry because they lend themselves easily to integration, vertical FET's have a number of advantages over horizontal FET's. Because channel length for vertical FET's is not a function of the smallest feature size resolvable by state-of-the-art lithographic equipment and methods (e.g. on the order of 0.25 micrometers), vertical FET's can be made with a shorter channel length (e.g. on the order of 0.1 micrometers) than horizontal FET's, thus providing vertical FET's the capability to switch faster and as well as a higher power handling capacity than horizontal FET's. There is also the potential for greater packing density with vertical FET's.
FET structures may include a single gate (e.g. for forming a single channel) or a pair of gates (e.g. for forming a pair of channels), with double-gate versions providing an advantage of an increased current carrying capacity (e.g. typically greater than twofold over the single-gate versions). A number of horizontal double-gate FET structures, particularly in the Silicon-On-Insulator (SOI) area, have been proposed. Such structures typically require a bottom gate at the back of the substrate in addition to the conventional top gate. Fabrication of such structures is difficult because the top and bottom gate must be aligned to within tolerances beyond the accuracy of state of the art lithographical equipment and methods, and because self-aligning techniques are frustrated by the layers between the top and bottom gates.
In addition, it is desirable to have a means for electrically contacting the body of the transistor (e.g. where the channel is formed). Such contact is critical for avoiding unwanted parasitic effects created by a body having a floating potential; floating body effects can be particularly problematical for SOI transistors. However, proposed horizontal double-gate FET schemes generally lack any means for contacting to the body of the transistor.
What is needed is a double-gate FET which solves the above mentioned problems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a vertical double-gate transistor structure which has a high current carrying capacity.
It is a further object of the present invention to provide a vertical double-gate transistor structure having an electrically conductive connection to the body wherein the channel is formed.
It is a further object still to provide a vertical double-gate transistor structure capable of being manufactured using known state-of-the-art fabrication techniques.
The present invention is directed to a vertical double-gate transistor and a method for making the same. In one embodiment of the invention, the transistor includes a substrate, over which is stacked source, channel, drain and dielectric layers. On a first end of the transistor a gate oxide and conductive gate are wrapped around the top and sides of the stacked layers. Electrical contacts may be provided on a second end of the transistor. In one embodiment the first end includes a plurality of fingers around which the gate oxide and conductive gate are wrapped.
In another aspect of the invention, a method for fabricating a vertical double-gate transistor is provided. The method includes the steps of obtaining a semiconductor substrate; forming on the semiconductor substrate a source layer; forming on the source layer a channel layer; forming over a portion of the channel layer at a first end of the channel layer an etch-stop layer; forming over the channel layer and the etch stop layer a drain layer; forming over the drain layer a first dielectric layer; forming over a portion of the source, channel and drain layers a gate dielectric and a conductive gate, thus forming an insulated stack having a first end including the etch stop and a second end including the gate oxide and conductive gate; forming over the conductive gate a conformal dielectric layer; removing a portion of the drain layer at the second end of the insulated stack to expose the etch stop layer, and removing portions of the source and channel layers unprotected by the etch stop layer, thereby forming a contact plateau in each of the source, channel and drain layers; forming sidewall spacers along the sides of the contact plateaus; and forming vertical contacts connected to each of the source, channel and drain contact plateaus.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may best be understood by reference to the following detailed description of the preferred embodiments and the accompanying drawings in which:
FIGS. 1A through 1I depict the fabrication steps in a preferred embodiment of the method of the present invention for forming a vertical double-gate field effect transistor.
FIGS. 2A through 2I depict the fabrication steps in a preferred embodiment of the method of the present invention as viewed from cross-section A--A' shown in FIG. 1A and correspond to the respective like-numbered FIGS. 1 and 3.
FIGS. 3A through 3I depict the fabrication steps in a preferred embodiment of the method of the present invention as viewed from cross-section B--B' shown in FIG. 1A and correspond to the respective like-numbered FIGS. 2 and 3.
FIG. 4 is a top view of another preferred embodiment of the present invention.
FIG. 5 is a simplified perspective view of a portion of the structure shown in FIG. 4.
FIG. 6 is a graph depicting threshold voltage as a function of channel layer doping and mesa width W.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the device in this illustrative embodiment of the invention is a CMOS device, particularly an enhancement mode NMOS FET. As will be appreciated by those having ordinary skill in the art, a similar PMOS FET can be fabricated in accordance with the teachings of the invention by using p-type dopants in place of n-type dopants and vice versa.
Referring to FIG. 1A there is shown a cross-sectional view of a semiconductor substrate 10. FIGS. 2A and 3A show the same device from corresponding respective cross-section A--A' at a first end 24 and cross-section B--B' at a second end 26 which correspondence to FIG. 1 carries through the remainder of FIGS. 2 and 3 (e.g. FIG. 1B corresponds to FIGS. 2B and 3B at cross-sections A--A' and B--B' respectively etc). The substrate 10 may be silicon, gallium arsenide, or another semiconductor material. The substrate 10 may be, for example, of the bulk or SOI type. If the substrate 10 is a bulk substrate, a p-type well (not shown) may be formed in the substrate 10. Next, formed over the substrate 10 is an n-type source layer 12, preferably an n+ type source layer, for reasons which will be explained below. The source layer 12 may be formed by a conventional ion implantation of the substrate 10 or by an epitaxial method known in the art.
With reference to FIGS. 1B, 2B and 3B, a p-type channel layer 14 is formed, preferably by a low-temperature epitaxial (LTE) method. For example, a suitable LTE method is disclosed in "Low-Temperature Silicon Epitaxy by Ultrahigh Vacuum/Chemical Vapor Deposition", by B. S. Meyerson, Appl. Phys. Lett. 48 (12), Mar. 24, 1986, pp. 797-799. LTE methods are preferred to form the channel layer 14 in order to avoid excessive out-diffusion from the n-type source layer 12, thereby permitting greater control over channel length than is afforded by other methods. The thickness of the channel layer 14 is preferably on the order of 1000 Å. In order to grow a high quality channel layer 14, it is preferable to cause the source 12 to be amorphized and then recrystallized early in the LTE process. The doping provided to the channel layer 14 by the LTE process is preferably in the range of 1×10 16 atoms/cm 3 to 3×10 18 atoms/cm 3 , depending on the desired threshold voltage.
With reference to FIGS. 1C, 2C and 3C, an etch-stop layer 16 is formed over a portion of the second end 26. The size and location of the etch-stop layer 16 may be defined lithographically, and should be dimensioned and toleranced to ensure coverage over an area of the channel layer 14 desired for forming thereon a body contact. The etch-stop layer 16 may be approximately 200 Å to 500 Å thick for eventual removal by an etchant having a selectivity ratio no less than 10:1 over the channel layer 14, and is preferably a dielectric and more preferably an oxide.
With continued reference to FIGS. 1C, 2C and 3C, an n-type drain layer 18, preferably an n+ type drain layer, is formed over the channel layer 14 and the etch-stop layer 16. The drain layer 18 is preferably formed by chemical vapor deposition (CVD) of polycrystalline silicon, followed by diffusion annealing. The diffusion annealing may comprise heating in an inert ambient environment at a temperature on the order of 800° C. to 1050° C., for example, rapid thermal annealing at 950° C. The combination of CVD followed by diffusion annealing allows for limited out-diffusion from the drain layer 18 into channel layer 14 and recrystallization of a portion of the polysilicon drain layer 18 near the channel layer 14 without losing control over the effective channel length, L eff (e.g. approximately equal to thickness of channel layer 14 less the out-diffusion exhibited by the drain layer 18 and the source layer 12).
With continued reference to FIGS. 1C, 2C and 3C, a passivation cap 28 is formed over the drain layer 18. The passivation cap 28 is preferably a dielectric formed by CVD from tetraethylorthosilicate (TEOS) at approximately 700° C. Next, the substrate 10 is patterned to form a transistor stack 32. The patterning controls the desired width W of the channel layer 14 (hereinafter referred to as the mesa width W; see FIG. 2C for identification of W) on the first side 24 of the transistor stack 32. For a completed transistor having an effective channel length, L ef , of approximately 1000 Å to operate in a fully-depleted mode (e.g. with merging depletion regions), the mesa width W should be preferably on the order of 300 Å to 1000 Å. Larger mesa widths may result in less than full-depletion or a threshold voltage V th which is extremely sensitive to the doping concentration of the channel layer 14. FIG. 6 shows the simulated sensitivity of the threshold voltage to channel layer doping for W=300 Å and W=1500 Å. It is evident from the graph that for doping below about 5×10 17 /cm 3 , a transistor having a mesa width W of 1500 Å punches through, resulting in loss of gate control and excessively low threshold voltage. In contrast, a relatively narrow mesa width W, such as 300 Å, provides the ability to lightly dope the channel layer 14, affording such advantages as high carrier mobilities and thus higher current carrying capacity, without sacrificing gate control. Mesa widths in the range of 300 Å to 1000 Å may be achieved by employing known sidewall image transfer techniques.
With reference to FIGS. 1D, 2D and 3D, a vertical gate oxide 30 is grown along the sides of the transistor stack 32, alongside each of the source layer 12, channel layer 14 and drain layer 18. The portions of the gate oxide 30 overlapping the source layer 12 and drain layer 18 can be made thicker than the portion of the gate oxide 30 overlapping the channel layer 14, to provide a smaller capacitance value relative to that provided by the oxide overlapping the channel layer 14, thus minimizing the input capacitance created by the gate oxide overlapping the source layer 12 and the drain layer 18. The oxidation conditions and doping of the source layer 12 and drain layer 18 may be selected in order to exploit variations in oxidation rates with the doping concentration of a semiconductor. For example, the oxidation rate of an n+ polysilicon layer (1.5×10 20 /cm 3 ) may be up to approximately 5 times as fast as the oxidation rate of a p- layer (1×10 16 /cm 3 ). If the drain layer 18 and source layer 12 are each doped at an n+ level while the epitaxial channel layer 14 is p-, the thickness of the portions of the gate oxide 30 which overlap the source layer 12 and the drain layer 18 may be approximately 5 times the thickness of the portion of the gate oxide which overlaps the channel layer 14.
With reference to FIGS. 1E, 2E and 3E, a conformal gate 34 and gate cap 36 can be formed over and wrapped around the sides of the transistor stack 32, forming a contiguous structure. The gate 34 must be conductive, is preferably polycrystalline silicon or tungsten, more preferably n+ polysilicon, or p+ polysilicon if a high threshold voltage is desired for a lower off-current, and may be formed by known CVD methods. The gate cap 36 should be a dielectric material and may be grown or deposited by known methods. The portions of the gate 34 and the gate cap 36 covering the second end 26 of the transistor stack 32 may then be removed such that the gate 34 and the gate cap 36 cover the exposed edges of only the first end 24 of the transistor stack 32. The removal may be achieved by applying a photosensitive material, patterning the photosensitive material such that the second end 26 of the transistor stack 32 is exposed, and etching the transistor stack 32 until the passivation cap 28 at the second end 26 is exposed. Forming the gate 34 in this manner avoids the alignment problems referred to hereinabove which problems are typically associated with horizontal double-gate transistors.
With reference to FIGS. 1F, 2F and 3F, another photosensitive layer 38 may be applied and patterned. The patterning of photosensitive layer 38 aligns inside edge 40 cooperatively with etch-stop layer 16 as shown in FIG. 1F. More particularly, a line extended from inside edge 40 would intersect etch-stop layer 16 a distance D from outside edge 42 of the etch-stop layer 16, the distance D roughly approximating the size of an electrical contact to be made to the channel layer 14. After patterning, the transistor stack 32 may be subjected to etching to remove portions of the source layer 12, the channel layer 14 and the drain layer 18 at the second end 26. A suitable reactive ion type etchant for an oxide etch-stop layer 16 should be selective to both oxide and photoresist, for example, HBr, or alternatively, HCl+Cl+O 2 +N 2 . As shown in FIGS. 1F, 2F and 3F, the portions of the drain layer 18 at the second end 26 which are not protected by the photosensitive layer 38 are completely removed. Etching is continued until the source layer 12 is exposed, but a portion of the channel layer 14 remains, having been protected by the etch-stop layer 16. After etching, plateaus 41, 43 and 45 have been formed for making contact respectively to the source layer 12, the channel layer 14 and the drain layer 18.
With reference to FIGS. 1G, 2G and 3G, the photosensitive layer 38 may be stripped from the transistor stack 32, and insulating sidewall spacers may be formed on exposed edges of the transistor stack 32. More particularly, sidewall spacers 44/52 have been formed along the exposed edges of the gate 34/cap 36. Similarly, sidewall spacers 46, 48 and 50 are formed respectively along the drain layer 18, the channel layer 14 and the source layer 12. The sidewall spacers 44, 46, 48, 50 and 52 may comprise nitride, formed, for example, by CVD followed by anisotropic etching. The use of nitride as the sidewall spacer material allows for a borderless contact scheme thus providing the advantage of more generous tolerances for placing contacts. However, if it is desired to apply silicide to the active regions to enhance the conductivity of the diffusion regions (e.g. source layer 12 and drain layer 18) to the conductive contacts to be formed (not shown), the sidewall spacers should be of a dielectric material rather than silicon nitride, to avoid shorting between layers.
With reference to FIGS. 1H, 2H and 3H, the entire transistor stack 32 is encapsulated in a dielectric material 54, preferably silicon dioxide, and patterned. Openings 56, 58, 60, 62 for contact studs are etched through the encapsulating dielectric material 54. Opening 58 extends through both the encapsulating dielectric 54 and the passivation cap 28, thereby exposing and permitting contact to the drain layer 18. Opening 60 extends through both the encapsulating dielectric material 54 and the etch-stop layer 16, thereby exposing and permitting direct contact to the channel layer 14 (e.g. body contact).
With reference to FIGS. lI, 2I and 3I, electrically conductive contact studs 57, 59, 61 and 63 are formed by CVD of a conductive material such as tungsten, as is known in the art.
FIG. 4 depicts a top view of another preferred embodiment of the present invention, in which like reference numerals indicate like features. The structure shown in FIG. 4 can be formed by the steps described above up through the description referring to FIGS. 1G, 2G and 3G (e.g. just prior to encapsulation and formation of contact studs 57, 59, 61 and 63). The transistor stack 132 shown in FIG. 4 includes a contact end 126, analogous to the second end 26 of the transistor stack 32 shown in FIGS. 1G, 2G and 3G, and an active end 124 analogous to the first end 24 shown in FIGS. 1G, 2G and 3G. The active end 124, however, is characterized by a plurality of fingers 164 each of which is analogous to the first end 24 of the transistor stack 32 shown in FIGS. 1G, 2G and 3G and which are joined at the contact end 126 in order to share contacts. The structure shown in FIG. 4 provides additional current carrying capacity in a dense layout. An exemplary vertical transistor made in accordance with the present invention may have for each of four fingers, a channel length of 1000 Å and a mesa width W of 300 Å, and a finger length of approximately 2000 Å.
Increasing finger length F can further increase the current carrying capacity of the transistor stack 132, but may be accompanied by undesirable increases in propagation delay. An alternate embodiment provides for an additional set of contacts by making the structure 132 symmetric about the line C--C' shown in FIG. 4, thus effectively doubling finger length F without increasing propagation delay. Such a technique could also be applied to single-finger versions of the invention, but would be less space efficient.
The above description includes specific exemplary dimensions for the preferred embodiment. However, the invention can be more broadly described by roughly approximating the relative relationships of the important dimensions. Depicted in FIG. 5 is a simplified representation of a multi-fingered transistor stack 232, for purposes of illustrating important dimensions. Shown in FIG. 5 is L eff , or effective channel length, determined by the thickness of the channel layer 214, and the overall height, h, of the transistor stack 232, which is characterized by the sum of the thicknesses of the source layer 212, the channel layer 214 and the drain layer 218. Also shown are the mesa width W, and finger length F, as identified. Table 1 below gives approximate favored ranges of dimensions and/or relationships between the identified dimensions: ##EQU1##
Various advantages over the prior art are provided by the invention herein described. Importantly, the invention provides a vertical transistor with direct contact to the channel layer 14 (e.g. body), an important characteristic for avoiding floating body effects in SOI devices. The invention further provides a transistor capable of carrying 2X or more that of a single-gate planar transistor, with increasing current as mesa width W is decreased, due to channel depletion effects. Short channel effects, with respect to L eff , are suppressed as mesa width W is decreased and the channel approaches full depletion. Furthermore, the alignment problems normally associated with double-gate transistors are avoided by the use of a wrap-around gate 34.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various other changes in form and detail may be made therein without departing from the spirit and scope of the invention. | A vertical double-gate field effect transistor includes a source layer, an epitaxial channel layer and a drain layer arranged in a stack on a bulk or SOI substrate. The gate oxide is thermally grown on the sides of the stack using differential oxidation rates to minimize input capacitance problems. The gate wraps around one end of the stack, while contacts are formed on a second end. An etch-stop layer embedded in the second end of the stack enables contact to be made directly to the channel layer. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to soil remediation equipment and, particularly, without limitation, to such equipment utilizing a combustion chamber in a rotating drum.
2. Description of the Related Art
Remediation of contaminated soil is, and will continue to be for the foreseeable future, a large and growing industry. For example, soil containing hydrocarbons due to service station ground leakage must be cleaned or removed before the property can be transferred. Companies that have developed equipment and experience for similar applications, such as asphalt plant plants, are a natural for providing the skills and facilities needed for soil remediation.
The generally applied method of remediating contaminated soil is to heat the soil with a large combustion heater to a sufficiently elevated temperature, such as approximately 500° F., in an inclined rotating drum, that gravitationally flows the soil continuously therethrough. The elevated temperature releases the contaminants--typically hydrocarbons, both short chain and long chain--from the soil by vaporization. The soil is then removed from the rotating drum and cooled for reuse.
The vapors, containing the contaminants and combustion products from the burner used to elevate the soil temperature, are usually directed, after filtering, into an afterburner. The afterburner generally comprises a second large burner that, in conjunction with the combustion properties of the contaminates, further elevate the temperature of the vapors in order to break down and oxidize contaminates remaining in the vapors. Short-chain or light hydrocarbons, such as those arising from service station leakage, vaporize at approximately 500° F. and require afterburning at approximately 1600° F.; long-chain or heavy hydrocarbons, such as those arising from coal gasification production, vaporize at approximately 1000° F. and require afterburning at approximately 2,000° F. The afterburned vapor, which is relatively clean, is cooled and/or filtered and exhausted into the atmosphere. Typically, such a described soil remediation system can treat 25 to 50 tons of contaminated soil per hour.
Similarly to long-chain hydrocarbon clean-up, clean-up of PCB contamination is more energy intensive than short-chain hydrocarbon cleanup.
One attempt to reduce energy consumption during soil remediation is disclosed in U.S. Pat. No. 5,170,726 wherein heat staging of soil contaminated with short-chain and long-chain hydrocarbons was utilized in an attempt to reduce the afterburning temperature to 1600° F. Unfortunately, however, the system was more complex in that not one, but two, drums were required. Soil is heated by a first large burner to approximately 500° F. in a first drum followed by cascading the heated soil into a second drum with a second large burner to further elevate the temperature of the soil and vapor to approximately 1000° F. The vapors containing long-chain hydrocarbons that were released at the 1000° F. of the high-temperature drum were then vented through the first large burner of the low-temperature drum to simultaneously afterburn the long-chain hydrocarbons during the first-stage heating of the contaminated soil in the first drum. Thus, in theory, the only hydrocarbons entering a separate afterburner were the short-chain hydrocarbons that were vaporized in the first drum. Unfortunately, energy consumption, although reduced, is still excessive.
What is needed is a soil remediation system that vaporizes and afterburns the volatilized contaminates--including short-chain hydrocarbons, long-chain hydrocarbons, and PCB's--with a single drum and a single burner to thereby substantially reduce energy consumption even further and to exhaust clean soil and clean vapor at a temperature of approximately 450° F.
SUMMARY OF THE INVENTION
An improved soil remediation system is provided for reducing energy consumption during use thereof to remediate contaminated soil containing short-chain hydrocarbons, long-chain hydrocarbons and/or PCB's. Briefly, the improved system comprises a single heat source; a single drum; recovery of thermal energy from hot, remediated soil; and recovery of thermal energy from the hot gas stream of oxidized contaminate vapors to thereby conserve energy.
The improved system includes a cylindrically shaped rotary drum having an outer shell with a first end and a second end, and first and second heat transferring regions. The rotary drum is inclined such that the first end is elevated relative to the second end.
The first heat transferring region includes a first heat transferring zone spaced internally within the outer shell and extending from the first end and terminating intermediately between the first end and the second end. The second heat transferring region includes a second heat transferring zone spaced internally within the outer shell and extending from the first heat transferring zone to the second end. An inner shell, spaced radially inwardly from the outer shell and generally co-extensive with the first heat transferring zone, has a tumbling region contained internally therein and forms an annular region between it and the outer shell.
A burner shell, spaced radially inwardly from the outer shell and being generally co-extensive with the second heat transferring zone, has a combustion chamber internally therein. An intermediate shell, spaced radially between the outer shell and the burner shell, forms an outer annular region between it and the outer shell and forms an inner annular region between it and the burner shell. The intermediate shell is connected to the inner shell such that contaminated soil is gravitationally urged from the inner shell into the intermediate shell. Spacers, that locate the inner shell and the intermediate shell relative to the outer shell, have an auger-like configuration to operatively urge remediated soil through the outer annular region and the annular region from the second end to the first end in counter-flow relation to the contaminated soil being gravitationally urged from the first end to the second end through the first and second heat exchanging zones. A transition component is connected to the second end such that a transition cavity is formed therein; the transition component has a generally conical shape with a truncated end.
A generally radial end plate connects the burner shell to the intermediate shell at the second end such that a peripheral opening is formed between the outer shell and the intermediate shell such that flow communication is established between the transition cavity and the outer annular region, the end plate having at least one clean soil opening establishing flow communication between the inner annular region and the transition cavity. The at least one clean soil opening is spaced adjacent to the burner shell. A plurality of clamshell ducts are connected to the end plate and extend longitudinally through the inner annular region, generally coextensive with the burner tube. Each of the plurality of clamshell ducts has a respective clean vapor opening establishing flow communication between each of the plurality of clamshell ducts and the transition cavity. Each of the plurality of clamshell ducts terminate at a respective inner end. A reversing duct interconnects the inner ends of the plurality of clamshell ducts with the inner end of the burner shell such that flow communication is established thereamong.
A shroud is spaced within the transition cavity. The shroud has an inner end thereof connected to the end plate between the at least one clean soil opening and the clean vapor openings. The shroud is configurated to direct vapor, flowing from the inner annular region into the transition cavity, toward the peripheral opening between the transition cavity and the outer annular region.
A burner tube extends through the truncated end and into the combustion chamber. A vapor return duct, connected to the end plate and encircling the burner tube, forms a first throat between the vapor return duct and the burner tube. The vapor return duct has a flared distal end spaced near the truncated end such that a second throat is formed between the distal end and the truncated end. An air duct encircles the burner tube such that a third throat is formed between the air duct and the burner tube. The air duct is displaceable along the burner tube to operably adjust the first throat. The apparatus includes a blower that operably moves a substantial volume of fluid at substantial velocity through the burner tube.
Sealed auger means operatively feeds contaminated soil into the tumbling region at the first end of the rotary drum. Soil discharge means discharge the remediated soil from the annular region at the first end; vapor discharge means discharge clean vapor from the annular region at the first end. The apparatus is adapted to operatively remediate contaminated soil and oxidize contaminates with a single burner, and to subsequently transfer heat from the remediate soil to incoming contaminated soil whereby the clean, remediated soil and the clean, oxidized contaminates are exhausted at a temperature of approximately 450° F.
The improved soil remediation system also provides a method for reducing energy consumption during remediation of soil contaminated with short-chain hydrocarbons, long-chain hydrocarbons, and/or PCB's. The method comprises the steps of providing an apparatus that includes an inclined rotary drum having a reactor end and an input/output end elevated relative to said reactor end, a first heat exchanging region having a first inner region and a first outer region surrounding and separated from the first inner region, a second heat exchanging region having a second inner region and a second outer region surrounding and separated from the second inner region, burner means adapted to remediate the contaminated soil by operatively and sufficiently elevating the temperature of the contaminated soil contained in the first inner region and the second inner region to vaporize and oxidize the short-chain hydrocarbons, the long-chain hydrocarbons, and/or the PCB's contained in the soil, sealed feeding means for introducing the contaminated soil into the apparatus, and auger means for conveying the soil that has been remediated by the apparatus through the second outer region and the first outer region in counter-flow relation to contaminated soil being gravitationally urged through the first inner region and the second inner region. The method further comprises introducing the contaminated soil into the first inner region near the input/output end by the sealed feeding means, rotating the inclined rotary drum to operatively and gravitationally urge the soil from the input/output end to the reactor end through the first inner region and the second inner region, operating the burner means to remediate the soil by operatively and sufficiently elevating the temperature of the soil contained in the first inner region and the second inner region to vaporize and oxidize the short-chain hydrocarbons, the long-chain hydrocarbons, and/or the PCB's contained in the soil introduced into the first inner region by the sealed feeding means, transferring the remediated soil and the oxidized short-chain hydrocarbons, long-chain hydrocarbons, and/or PCB's vaporized from the soil to the second outer region at the reactor end of the rotary drum, conveying and urging the remediated soil through the second outer region and the first outer region by the auger means and the oxidized short-chain hydrocarbons, long-chain hydrocarbons, and/or PCB's vaporized from the soil to operatively transfer thermal energy from the remediated soil contained in the second outer region and the first outer region to the soil being gravitationally urged through the first inner region and the second inner region, to substantially reduce the temperature of the remediated soil prior to discharge of the remediated soil from the apparatus, and to discharge the remediated soil from the apparatus.
The method further includes reducing the temperature of the remediated soil prior to discharge thereof such that the discharged clean soil and the exhausted clean vapor has a temperature of approximately 450° F.
PRINCIPAL OBJECTS AND ADVANTAGES OF THE INVENTION
The principal objects and advantages of the present invention include: providing an apparatus and method for soil remediation wherein only one burner is required; providing such an apparatus and method that substantially reduces energy requirements without reducing the rate at which contaminated soil is being remediated; providing such an apparatus and method wherein only one rotary drum is required; providing such an apparatus and method wherein only one heat source is required; providing such an apparatus and method wherein thermal energy contained in the soil after remediation and the oxidized contaminates vaporized from the contaminated soil are used to sufficiently heat the soil before remediation to vaporize short-chain hydrocarbons therein; providing such an apparatus and method wherein clean, oxidized vapor from contaminated soil is used to urge remediated soil in counter-flow, heat-transferring relation with gravitationally urged contaminated soil; and generally providing such an apparatus and method that are reliable in performance, and are particularly well adapted for the proposed usages thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a prior art soil remediation system.
FIG. 2 is a side elevational view of an energy recuperative soil remediation system, according to the present invention.
FIG. 3 is a schematic cross-sectional view of the energy recuperative soil remediation system.
FIG. 4 is an enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 4--4 of FIG. 3.
FIG. 5 is another enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 5--5 of FIG. 3.
FIG. 6 is still another enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 6--6 of FIG. 3.
FIG. 7 is an enlarged and fragmentary, longitudinal cross-sectional view of the energy recuperative soil remediation system, according to the present invention.
FIG. 8 is a schematic diagram of the energy recuperative soil remediation system, according to the present invention.
FIG. 9 is another enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 9--9 of FIG. 7.
FIG. 10 is another enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 10--10 of FIG. 3.
FIG. 11 is another enlarged cross-sectional view of the energy recuperative soil remediation system, taken along line 11--11 of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
A description of the process flow of a prior art soil remediation plant, as schematically shown in FIG. 1, can be briefly described as follows. Assume a vaporizing burner 1 and an afterburner 3 of the prior art plant is operated with 25% excess air to remediate contaminated soil 5 containing about 10% moisture at the rate of forty tons per hour. For such a prior art example, the vaporizing burner 1 typically consumes fuel at the rate of approximately 47.4 million BTU's per hour amd the afterburner 3 typically consumes fuel at the rate of approximately 55.9 million BTU's per hour, for a total consumption in excess of approximately 110 million BTU's per hour at a current annual cost on the order of approximately $750,000 per year fuel cost. In addition to the excessive fuel costs of such a prior art soil remediation plant, physical size of and emissions from the plant are directly related to the size of the burners 1 and 3 and of the fuel flow requirements of the burners 1 and 3.
Further, as vapor 7 evaporated in a rotary drum 9 by the burner 1 contains contaminates, the vapor 7 is generally processed through a filter 11 before the vapor 7 is directed to the afterburner 3. As equipment normally used for the filter 11 cannot withstand a temperature of 1000° F., the rotary drum 9 of the exemplary prior art soil remediation system is generally operated in counterflow fashion in order to cool the vapor 7 down to approximately 475° F. by interaction with the contaminated soil 5 in the rotary drum 9. As a result, the contaminated vapor 7 is, in essence, cooled down from approximately 1000° F. before introduction into the filter 11 only to be re-heated up to approximately 2000° F. afterward in the afterburner 3 to provide a vapor 13 that is free from both short-chain and long-chain hydrocarbons, which represents an obvious waste of energy.
Another approach to reclaim some of the otherwise wasted energy has been to pre-heat pre-afterburner vapor 15 with the post-afterburner vapor 13 by use of an air-to-air heat exchanger, such as a heat exchanger having ceramic surfaces. By pre-heating the pre-afterburner vapor 15, such as to approximately 1500° F., by interaction with the post-afterburner vapor 13, some energy savings would, indeed, be realized. Unfortunately, this approach ignores, and is incapable of, recouping any of the thermal energy stored in the cleaned or remediated soil 17 as it exits from the rotary drum 9 at a temperature of approximately 1000° F. Instead, the soil 17 is processed through a cooler 19 wherein water 21 is sprayed on clean soil 17, 23 passing therethrough for cooling purposes. The magnitude of nonrecovered thermal energy represented by the elevated temperate of the soil 17 is on the order of approximately one million BTU per ton per hour, or approximately forty million BTU's per hour of wasted thermal energy for the forty-ton/hour plant.
The reference numeral 101 generally refers to an energy recuperative soil remediation system in accordance with the present invention, as shown in FIGS. 2 through 8. The system 101 generally includes a cylindrically shaped, heat exchanger or rotary drum 103 supported on frame means 105. The frame means 105 generally comprises a pair of spaced apart, parallel beams 107, inclined from a horizontal orientation and supported by vertical legs 109. Mounted on the parallel beams 107 are a plurality of motor driven rollers 111 that supportingly receive trunnion rings 113 secured to the exterior surface of the rotary drum 103, as shown in FIG. 2. Rotation of the drive rollers 111, as engaged with the trunnion rings 113, causes the rotary drum 103 to be rotated about an axis, as designated by numeral 115 in FIG. 2.
The rotary drum 103 has a first-stage or preliminary heat transferring zone 117 extending interiorly inwardly from a first or input/output end 119 of the rotary drum 103 along the longitudinal axis 115 thereof, and a second-stage or reactor heat transferring zone 121 extending from adjacent to the first-stage heat transferring zone 117 to a second or reactor end 123 of the rotary drum 103.
Substantially throughout the first-stage heat transferring zone 117, the rotary drum 103 has a double shell structure 125 with an outer shell 127 and an inner shell 129, that has a tumbling region 131 situated interiorly of the inner shell 129 and an annular region 133 situated between the outer shell 127 and the inner shell 129.
The inner shell 129 is longitudinally configured to substantially increase, and perhaps maximize, the surface area that the inner shell 129 provides between the tumbling region 131 and the annular region 133. The configuration of the inner shell 129, as shown in FIG. 4, depicts eight deep longitudinal ribs 135 and eight shallow longitudinal ribs 137 interposed therebetween. It is to be understood that more or fewer in number of the longitudinal ribs 135 and 137 may be required for a particular application. In addition, some applications may require that the longitudinal ribs 135 and 137 be substantially similar as opposed to having both the deep longitudinal ribs 135 and the shallow longitudinal ribs 137. It is to be further understood that, within the nature and spirit of the present invention, the inner shell 129 may be configured with a multitude of other profiles rather than that shown in FIG. 4.
The longitudinal axis 115, about which the rotary drum 103 is rotated, is inclined such that the input/output end 119 is elevated above the reactor end 123. The rotary drum 103 is sufficiently inclined whereby contaminated soil 139 deposited into the input/output end 119 of the rotary drum 103, such as by an auger 141 through a sleeve extension or input port 143 spaced centrally along the axis 115, as shown in FIGS. 2 and 3, is gravitationally urged from the input/output end 119 toward the reactor end 123 of the rotary drum 103. The auger 141 independently rotates inside of the sleeve extension 143 such that a positive pressure seal is operatively provided between the auger 141 and the sleeve extension 143.
Attached to the outer shell 127 in the first-stage heat transferring region 117 are a plurality of spacers 145 that are dimensioned to maintain the spacing of the inner shell 129 relative to the outer shell 127. The spacers 145, which are shown schematically in FIG. 4, have an auger-like configuration in order to urge soil 166 contained in the annular region 133 toward the input/output end 119, counter to the gravitationally urged, direction of travel of the contaminated soil 139 contained in the tumbling region 131.
Substantially throughout the second-stage heat transferring zone 121, the rotary drum 103 has a triple shell structure 147: the outer shell 127, an intermediate shell 149, and a combustion chamber shell 15 1, as shown in FIG. 7, such that an outer annular region 153 is situated between the outer shell 127 and the intermediate shell 149, an inner annular region 155 is situated between the intermediate shell 149 and the combustion chamber shell 15 1, and a combustion chamber or oxidizer 156 is situated interiorly to the combustion chamber shell 151. The annular region 133 of the first-stage heat transferring zone 117 opens directly into the outer annular region 153 of the second-stage heat transferring zone 121, and the tumbling region 131 of the first-stage heat transferring zone 117 opens directly into the inner annular region 155 of the second-stage heat transferring zone 121.
Attached to the reactor end 123 of the rotary drum 103 is a transition component 157, which is generally configured in the shape of a truncated cone having a transition cavity 159 therein, as shown in cross-section in FIG. 7. The outer annular region 153 opens directly into the transition cavity 159 through a peripheral opening 160. Except for one or more openings 161 spaced adjacent to the combustion chamber shell 15 1, the inner annular region 155 is closed off from the transition cavity 159 by an end plate 163, as shown in FIG. 5.
Attached to the outer shell 127 in the second-stage heat transferring region 121 are a plurality of spacers 165 that are dimensioned to maintain the spacing of the intermediate shell 149 relative to the outer shell 127. The spacers 165, which are shown schematically in FIG. 5, have an auger-like configuration in order to urge clean soil 166 contained in the outer annular region 153 from the second-stage heat transferring region 121 to the first-stage heat transferring region 117, counter to the gravitationally urged direction of travel of the contaminated soil 139 traveling through the inner annular region 155.
Spaced, at least partially, within the transition cavity 159 are a generally cylindrical burner tube 167, a generally cylindrical vapor return duct 169 that surrounds and is generally coaxial with the burner tube 167, a generally cylindrical fresh air duct 171 that also surrounds and is generally coaxial with the burner tube 167, and a clean vapor shroud 173 that is also generally coaxial with the burner tube 167.
The vapor rerurn duct 169 has a flare 175 forming an outer throat 177 in the transition cavity 159 near a truncated end 179 of the transition component 157 and an inner throat 181 alongside the burner tube 167 such that contaminated vapor contained in the transition cavity 159 can be drawn into the oxidizer 156 as hereinafter described.
The fresh air duct 171 has a flange 185 that forms a throat 187 alongside the burner tube 167 to provide outside, combustion air that can be forced or drawn into the oxidizer 156. The flange 185 is configured, relative to the vapor return duct 169, whereby the effective cross-sectional area of the inner throat 181 can be decreased by axially displacing the fresh air duct 171 toward the vapor return duct 169 and decreased by axially displacing the fresh air duct 171 away from the vapor return duct 169. Thus, the mixture ratio of fresh air forced or drawn through the throat 187 to the contaminated vapor being drawn through the inner throat 181 can be selectively adjusted as desired.
Inner ends 189 of a plurality of hollow clamshell ducts 191 extend from an inner end 192 of the burner tube 167 to the end plate 163. Each of the clamshell ducts 191 flow communicate with the transition cavity 159 through a respective clamshell opening 193 through the end plate 163, as shown in FIG. 5. Each of the inner ends 189 are connected in flow communication with each other and with the inner end 192 by a reversing duct 195 such that fluid flowing axially inwardly through the burner tube 167, as indicated by the arrow designated by the numeral 196 in FIG. 3, and through the inner end 192 must reverse and flow in the opposite direction through the clamshell ducts 191, as indicated by the arrows designated by the numeral 197 in FIG. 3, and into the transition cavity 159 through the clamshell openings 193.
A cross-sectional view taken along line 9--9 of FIG. 7 generally centrally through the second-stage heat exchanging zone 121 is shown in FIG. 9. Also, a cross-sectional view taken along line 10--10 of FIG. 3 through the, reversing duct 195 is shown in FIG. 10. Further, a cross-sectional view taken along line 11--11 of FIG. 3 between the reversing duct 195 and the first-stage heat exchanging zone 117 is shown in FIG. 11.
The configuration of the system 101, as shown in FIG. 5, depicts sixteen of the clamshell ducts 191. It is to be understood that more or fewer in number of the clamshell ducts 191 may be required for a particular application. In addition, some applications may require that the clamshell ducts 191 have a shape different from the elongated cross-sectional configuration shown in FIG. 5.
The clean vapor shroud 173 is profiled to direct clean vapor exiting from the oxidizer 156 through the clamshell openings 193 into the transition cavity 159, as indicated by the arrows designated by the numerals 198 and 199 in FIG. 3, toward the peripheral opening 160 between the transition cavity 159 and the outer annular region 153. Preferably, the burner 167 is of the jet type in order to move large volumes of combustion products at relatively high velocity through the openings 193.
In an application of the present invention, pre-screened contaminated soil 139 is axially forced into the first-stage heat transferring zone 117 near the input/output end 119 by the auger 141. As the contaminated soil 139 drops into the first-stage heat transferring zone 117, it is subjected to temperatures on the order of 200° F. or more by heat transfer through the inner shell 129 from clean soil 166 being displaced through the annular region 133 toward the input/out end 119, as hereinafter described.
As the contaminated soil 139 is gravitationally urged toward the second-state heat transferring zone 121 by the tumbling action of the inclined rotary drum 103, the temperature of the contaminated soil 139 is progressively elevated due to heat transfer predominantly by conduction from the clean soil 166 through contact of the contaminated soil 139 with the inner shell 129. As the contaminated soil 139 passes from the first-stage heat transferring zone 117 into the second-stage heat transferring zone 121, the contaminated soil 139 has reached a temperature of approximately 400°-500° F. such that substantially all moisture in the contaminated soil 139 has been convened into steam and most of the short-chain hydrocarbons contained in the contaminated soil 139 have been vaporized.
As the contaminated soil 139 continues to be gravitationally urged through the second-stage heat transferring zone 121 toward the reactor end 123 by the tumbling action of the inclined rotary drum 103, the temperature of the contaminated soil 139 is further progressively elevated due to heat transfer by radiation from the intermediate shell 149, the combustion chamber shell 151, and the clamshell ducts 191; and by conduction through contact of the contaminated soil 139 with the intermediate shell 149, the combustion chamber shell 151, and the clamshell ducts 191.
As the contaminated soil 139 progresses through the second-stage heat transferring zone 121, the contaminated soil 139 and the accompanying steam and short-chain hydrocarbons are further heated to approximately 1000° F., which results in long-chain hydrocarbons and/or PCB's contained in the contaminated soil 139 also being vaporized. The steam and vaporized hydrocarbons and PCB's, having been released from the contaminated soil 139, readily pass through the openings 161 into the transition cavity 159.
Due to the radially inwardly spacing of the openings 161 from the intermediate shell 149, the soil 139 ramps backwardly into the second-stage heat transferring zone 121 from the end plate 163 until the depth of the ramped contaminated soil 139 abutting the end plate 163 reaches the openings 161, whereupon the previously contaminated soil 139--now clean soil 166--spills into the transition cavity 159 and falls downwardly against the cortically shaped transition component 157, as indicated by the arrow designated by the numeral 201 in FIGS. 3 and 7.
Due to the conical configuration of the transition component 157 and the rotary motion thereof, the clean soil 166 is gravitationally urged back toward the peripheral opening 160 into the outer annular region 153 between the intermediate shell 149 and the outer shell 127.
The residence time of the contaminated soil 139 in the second-stage heat transferring region 121 and the temperature at which the clean soil 166 exits the second-stage heat transferring region 121 can be controlled by selectively altering a variety of variables, including the rate of rotation of the rotary drum 103, the magnitude of the radial displacement of the openings 161 from the intermediate shell 149, the degree of incline of the rotary drum 103 from a horizontal orientation, and the burn rate of the burner 167.
The steam and vaporized hydrocarbons and PCB's which exit from the inner annular region 155 into the transition cavity 159 through the openings 161 are drawn into the oxidizer 156 through the outer and inner throats 177 and 181 to be heated to approximately 2000° F. and oxidized by the burner 167 in a stream of hot gases. The inner throat 181 can be regulated as desired by axially adjusting the fresh air duct 171 relative to the vapor return duct 169 in order to provide appropriate outside air for combustion of the hydrocarbons and PCB's in the oxidizer 156. As a substantial quantity of steam and vapors must be jet pump drawn into the burner 167, a high pressure double-stage combustion air blower 203 may be required for some applications.
Hot combustion products, from the burner 167 and from oxidizing the hydrocarbons and PCB's oxidized in the oxidizer 156 travel through the oxidizer 156, as the stream of hot gases, in a direction counter to the direction in which the contaminated soil 139 travels through the inner annular region 155. As the stream of hot gases comprising hot combustion products and oxidized contaminates 196 reach the reversing duct 195, they are deflected back into the clamshell ducts 191. The stream of hot gases comprising hot combustion products and oxidized contaminates--now clean vapor 198, 199--enter the clamshell ducts 191 at a temperature of approximately 2000° F. and, while transversing the clamshell ducts 191, are cooled to approximately 1100° F. due to heat transfer to the contaminated soil 139 through the clamshell ducts 191.
Upon exiting from the openings 161 in the end plate 163, the clean vapor 198, 199 is directed by the clean vapor shroud 173 toward the peripheral opening 160 between the transition cavity 159 and the outer annular region 153. By so directing the clean vapor 198, 199, a portion of the clean vapor 198, 199 flushes the contaminated vapor away from the peripheral opening 160 to thereby prevent recontamination of the clean soil 166 contained in the outer annular region 153 and the annular region 133. Also, a portion of the clean vapor 198, 199, entering the clean soil 166 between the clean vapor shroud 173 and the end plate 163, passes under the clean vapor shroud 173 and flushes out the contaminated vapor that may have been swept along with the clean soil 166 as it fell through the transition cavity 159 from the openings 161 to the inner conical surface of the transition component 157, as hereinbefore described.
The remaining portions of the clean vapor 198 and 199 join with the clean soil 166 to enter the outer annular region 153. The auger-configuration of the spacers 165, aided by the high-gas-velocity fluidization of remaining portions of the clean vapor 198 and 199 urges the clean soil 166 up the incline of the rotary drum 103. As the clean soil 166 is urged through the second-stage heat transferring zone 121, the clean soil 166 may undergo some cooling as heat is transferred through the intermediate shell 149 from the clean soil 166 and the clean oxidized vapor to the contaminated soil 139 moving in the opposite direction through the inner annular region 155.
As the clean soil 166 passes from the outer annular region 153 of the second-stage heat transferring region 121 into the annular region 133 of the first-stage heat transferring region 117, the auger-configuration of the spacers 145, assisted by the remaining portions of the clean vapor 198 and 199, continue to urge the clean soil 166 up the incline of the rotary drum 103 toward the input/output end 119. As the clean soil 166 is urged through the first-stage heat transferring zone 117, the clean soil 166 is cooled as heat is transferred through the inner shell 129 from the clean soil 166 to the contaminated soil 139 moving in the opposite direction through the tumbling region 131.
As the clean soil 166 and the remaining portions of the clean vapor 198 and 199 reach the input/output end 119, they have been cooled to clean soil 207, that exits at a temperature of approximately 450° F. through a clean soil exit port 209, and clean vapor 198, 199, that exits at a temperature of approximately 450° F. through a clean vapor exit port 213, as indicated by the arrow designated by the numeral 211 in FIG. 2. In some applications, it may be desirable that the clean soil 207 and the clean vapor 211 exit through the same exit port.
If additional cooling is needed, the clean soil 207, being at approximately 450° F., requires substantially less water for further cooling than is required to cool clean soil at approximately 1000° F., as normally provided by prior art soil remediation systems. Similarly, the clean vapor 211, also being at approximately 450° F., may require no further cooling before being processed through a filter 215 and released to the atmosphere as clean exhaust 217.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. | An improved system for remediating soil contaminated with short-chain hydrocarbons, long-chain hydrocarbons and PCB's. The system includes an rotary drum having first and second heat exchanging regions, each containing separated inner and outer regions. The drum in inclined such that soil fed into the system with a sealed auger for remediation is gravitationally urged through the inner regions whereat thermal energy provided by a burner means, including clamshell ducts, remediates the soil by vaporizing and oxidizing the hydrocarbons and PCB's in a stream of hot gases. After remediation, the soil and the stream of hot gases is transferred to the outer regions whereat the soil is auger-conveyed and fluid-flow urged therethrough, in counter-flow relation to the gravitationally urged soil in the inner regions, to transfer thermal energy from the remediated soil and stream of hot gases to the soil being remediated, to reduce the temperature of the remediated soil and the stream of hot gases prior to discharge, and to discharge the remediated soil and the stream of hot gases. An improved method is similarly provided. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/099,176, filed on Apr. 4, 2005 now abandoned, which claims priority to Russian Patent Application No. RU 2004110701 filed on Apr. 9, 2004, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of cell biology. In detail it relates to the obtainment of mesenchymal stem cells from human tissue. This invention might be applicable in healing within the frame of the treatment of several diseases.
2. Related Prior Art
Currently in biomedical sciences a new field is developing: cell therapy. By means of cell transplantation insufficient activities of tissue functions can be redressed and affected organs can be regenerated. The function of renewal and restoration is taken over from stem cells in vivo which form an agglomeration of non-differentiated precursors of different cells types which are kept in reserve. As a result of this the use of stem cells is a promising field of cell therapy. In this connection of particular importance is the obtainment of stem cells from human tissue.
At present one has been succeeded in obtaining different types of stem cells from the adult human organism. In detail they concern hematopoietic (blood cell precursors), neuronal (precursors of nerve tissue cells), mesenchymal cells (cells which are capable to differentiate into cells of mesenchymal origin as well as into other embryonic layer cells) and other.
It is characteristic for mesenchymal stem cells that they can be obtained and cultivated comparatively easily; they are also capable to proliferate in vitro over prolonged periods of time. Furthermore, they excel in a broad spectrum of differentiation. In this connection the attention is especially directed to the obtainment of mesenchymal stem cells from the adult human organism. However, till this day there is no universal method for the obtainment of stem cells.
For the first time stern cells could be obtained from the spinal marrow due to their ability of adhering to the surface of culture dishes (Fridenshtein A. J., Deriglazova U. F., Kulagina N. N. et al. Precursors for fibroblasts in different populations of hematopoietic cells as detected by the in vitro colony assay method. Exp. Hematol. 1974 Vol. 2. P. 83-92).
The disadvantage of this method consists in the lacking homogeneity of the obtained cell population. Nevertheless the adhesion of mesenchymal stem cells to plastics has been established as starting basis for further improved methods for obtaining mesenchymal stem cells.
A method for obtaining mesenchymal stem cells is known that results from the cells' ability of adhering to the surface of culture dishes, whereby specific batches of the embryonic bovine serum are used. Thus it was managed to obtain cells with a high ability of adhesion, high rate of proliferation and long maintaining multipotency (Heynesworth S. E., Goshima J., Goldberg V. M., Calplan A. I. Characterization of cells with osteogenic potential from the human bone marrow//Bone. 1995. Vol. 13. P. 81-85.)
The disadvantage of this method consists in the fact that the analysis of the serum during the search for a batch that is suitable for the cultivation of cells plenty of time and work is required; furthermore the reproduction of results is not possible.
It is known to obtain mesenchymal stem cells by a method by means of which a selection for antibodies against Stro-1 (antigen with unknown function) is performed, Stro-1 is temporarily expressed on the surface of mesenchymal stem cells (Grontos S., Simmons P. J. The growth factors requirements of Stro-1 positive human stromal precursors under serum-deprived conditions in vitro//Blood. 1995. Vol. 85. P. 929-940).
This method concerns an extreme complex process that is very time consuming due to the preliminary antibody preparation.
A method for obtaining mesenchymal stem cells is known by means of which mononuclear cells are obtained by centrifugation in a Ficoll gradient, a selection for antibodies against the surface antigen CD105 which is expressed on the surface of mesenchymal stem cells, as well as by a cultivation of cells which adhere to plastics. The portion of CD105 + cells amount to 2 to 3% of the mononuclear cells. As a result it was possible to obtain a cell population which shows the morphology and the expression profile of the surface antigens which are characteristic for mesenchymal stem cells and which also have chondregenic potential (Majumdar M. K., Banks V., Peluso D. P., Morris E. A. Isolation, characterization, and chondregenic potential of human bone marrow-derived multipotential stromal cells//J. Cell. Physiol. 2000. Vol. 185. P. 98-106).
This method enables the obtainment of the CD105 + cell fraction which is enriched in mesenchymal stem cells; however, this method requires an additional selection stage in which antibodies immobilized to magnetic beads are used. Thereby a portion of cells gets lost so that additional efforts are required.
It is known that with increasing age the number of mesenchymal stem cells in the human organism is diminished conspicuously. This also apply to their ability to proliferate and differentiate (Rao M. S., Mattson M. P. Stem cell and aging: expanding the possibilities//Mech. Ageing Dev. 2001. Vol. 122. P. 713-734). For this reason one is working on the preparation of mesenchymal stem cells with high proliferative activity and potential for differentiation, which are for example originating from fetal tissue or larvae organs, respectively.
A method for obtaining mesenchymal stem cells from fetal progeny blood is known in the art. To obtain them the mononuclear cell fraction is prepared by centrifugation in the Ficoll gradient and they are cultivated under conditions which are beneficial for the growth of mesenchymal stem cells. The so obtained cells show osteogenetic or adipogenetic potential, respectively (Campagnoli C., Roberts I. A., Kumar S. et al. Identification of mesenchymal stem/progenitor cells in human first trimester fetal blood, liver, and bone marrow//Blood. 2001. Vol. 98. P. 2396-2402).
The disadvantage of the obtainment of mesenchymal stem cells from this source consists in the fact that fetal tissue is problematic in view of its accessibility. Moreover one has to face ethic problems which are associated with its use. Furthermore, it has turned out that the obtained cell populations are not homogeneous: 76% of the samples contained osteoclast-like cells; they expressed the characteristic antigens CD45, CD51/CD61, and were negative for CD64 (marker for macrophages), SH2 (marker for mesenchymal stem cells), CD31 (marker for endothelial cells). Only 26% of the samples were composed of cells which were similar to mesenchymal stem cells and expressed SH2, SH3, SH4, MAB1470, CD13, CD29, CD49e, CD54, CD90, ASMA, and were negative for CD31 and vWF (marker for endothelial cells).
Known is the method for obtaining mesenchymal stem cells from the subendothelial layer of the umbilical vein (Romanov Y. A., Svinitskaya V. A., Smirnov V. N. Searching for alternative sources of postnatal human mesenchymal stem cells; candiate MSC-like cells from umbilical cord//Stem Cells. 2003. Vol. 21. P. 105-110). For these purposes the umbilical vein was treated inside with a collagenase IV solution for a short time (for 15 minutes). The so obtained cells were cultivated in DMEM-LG supplemented with 10% FBS. In this manner a cell population with fibroblast-like morphology was obtained; it expressed a range of antigens which was similar to mesenchymal stem cells: ICAM1 +/− , VCAM1 + , CD34 − ; MySM − (smooth muscle myosine); CD31 − , vWF − (marker for endothelial cells); CD14 − , CD45 − , CD68 − (marker for monocytes/macrophages), however it did express smooth muscle fibre actin ASMA. The so obtained cell population showed osteogenetic or adipogenetic potential in vitro.
The disadvantage of this method consists in the heterogeneity of the obtained cell population: The primary culture contained endothelial and smooth muscle cells, whereby the endothelial cells have not proliferated under these conditions, whereas the myocytes portion was maintained during the cultivation.
A method for obtaining mesenchymal stem cells from human lipoaspirate is known in the art. In this method fat tissue reduced to small pieces is exposed to the effect of collagenase (type I). After neutralization of the collagenase and rinsing of the cell suspension a purification is performed in order to remove cell residues by the use of filters having a pore size of 100 μm. By doing so a population of mesenchymal stem cells could be obtained that showed a characteristic morphology, immunophenotype and that was able to differentiate into bone, cartilage, fat, muscle or nerve tissues, respectively (Zuk P. A., Zhu M., Ashjian P., De Ugarte D. D., Huang J. I., Mizuno H., Alfonso Z. C., Fraiser J. K. Benhaim P. and Hedrick M. H. Human adipose tissue is source of multipotent stem cells//Molecular Biology of the Cell. 2002. Vol. 13. P. 4279-4295).
This method has the disadvantage that the obtained cell suspension is heterogenous and the yield is low.
SUMMARY OF THE INVENTION
With the present invention it is now possible to obtain mesenchymal stem cells from human tissue, whereby the cell suspension has a high homogeneity.
Against this background, an object of the present invention is a method for obtaining and/or isolating mesenchymal stem cells from human tissue, comprising the following steps: (a) providing human tissue, (b) enzymatical and mechanical treatment of said human tissue for obtaining a cell suspension, (c) removal of erythrocytes from said suspension, and (d) filtration of said suspension for obtaining mesenchymal stem cells, wherein in step (a) fat tissue or/and placenta tissue is used as human tissue.
Within the frame of the method for obtaining mesenchymal stem cells from human tissue fat tissue or placenta is used as human tissue. This method might comprise the crushing and enzymatic treatment of the tissue with a solution of collagenase in Eagle medium in the Dulbecco modification, the removal of erythrocytes by the aid of lysing buffer solution and the subsequent filtration of the obtained suspension. The filtration can be performed sequentially by means of filters comprising a pore size of 100 μm and 10 μm. The filtration step can be performed by the use of a first filter comprising a pore size of 100 μm in diameter, and the subsequent use of a second filter comprising a pore size of 10 μm in diameter.
Collagenase type I can be used for the enzymatic treatment of the fat tissue, the decidual or amniotic membrane of the placenta. For the enzymatic treatment of the stroma of the chorionic placenta collagenase type IV is used.
The technical results of the invention (increase of the homogeneity of the cell suspension, increase of the yield of the target product and improved viability of the cells) attribute to the conditions for the filtration: Specific size of the filter pores and specific ratio of the pores of the used filters. The change (increase or decrease) of these parameters will have the result that the stated technical results will not be achieved, since in this case the yield of the target product and the homogeneity of the obtained cell suspension will be conspicuously reduced. In comparison to known similar methods a multiple yield of cells can be obtained. According to the applicant by performing the known methods the yield amounts to 10 4 cells each tissue sample having a mass of 1 gram, whereas by performing the method according to the invention the yield of cells amounts to between 1.5 to 3×10 4 and 10 7 cells each 1 gram of several tissue samples. The increase of the homogeneity of the cell suspension is proved by the data of the morphological analysis and the determination of the immunophenotype. According to the data of the applicant by using the known method by which the population of mesenchymal stem cells is obtained from lipoaspirate, the population contains multiple morphological cell types; not before the 4 th passage the culture becomes homogenic in view of their cell shape and granulation or the expression of surface markers, respectively.
The method is realized as follows:
First of all a tissue sample is rinsed with physiological saline solution with phosphate buffer (PBS) at pH 7.2 without Ca 2+ and Mg 2+ ions, supplemented with antibiotics (penicillin 100 units/ml, streptomycin 100 microgram/ml) and antimycotics (amphotericin B 0.25 microgram/ml). The tissue to be treated is reduced to small pieces; the eagle medium in the Dulbecco modification with above-mentioned antibiotics and antimycotics is added with a volume ratio between tissue and medium of 1:5 to 1:10 (DMEM, Dulbecco's Modified Eagle Medium). For the enzymatic treatment collagenase solution is added to the suspension until a final concentration of 0.075% is reached. The suspension is incubated for 30 minutes at 37° C., whereby the suspension is swung carefully.
The so prepared mixture is agitated until a homogenic suspension is produced; subsequently for neutralization of the collagenase an equivalent volume of the DMEM medium is added to the prepared mixture, which contains 10% by volume of fetal bovine serum (FBS). Afterwards a centrifugation at 1000 g for 10 minutes is performed. The pellet is resuspended in the erythrocyte lysis buffer solution (155 mM NH 4 Cl, 10 mM KHCO 3 , 0.1 mM Na 2 EDTA). The mixture is thoroughly mixed and incubated for 3 to 5 minutes at room temperature.
The suspension is diluted with an equivalent volume of the DMEM medium that contains antibiotics and antimycotics; subsequently the cells are pelleted by centrifugation for 10 minutes at 1000 g. The pellet is rinsed with DMEM medium and again pelleted by centrifugation in the manner as described. The cells are brought into suspension in DMEM-LG medium with a concentration of glucose of 1 g/l, supplemented with 20% FBS, antibiotics and antimycotics. The so prepared cell suspension is filtered by the use of filters comprising a pore size of 100 μm and 10 μm, and 1 million cells each are plated per 1 cm 2 .
The so obtained cell population is characterized by the high homogeneity of mesenchymal stem cells, whereby the alteration of the filtration data (increase and/or decrease of the pore size) results in a reduction of the homogeneity of the target product or the yield of cells, respectively.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention is illustrated by the following embodiments:
Example 1
The decidual membrane is separated from the placenta by means of small scissors. A tissue sample of 2 g is rinsed with PBS (Gibco) at pH 7.2 without Ca 2+ and Mg 2+ ions for three times, whereby the PBS contains a one-fold solution of antibiotics or antimycotics (Gibco), respectively, in which the final concentration of penicillin is 100 units/ml, streptomycin 100 microgram/ml, amphotericin B 0.25 microgram/ml.
The tissue is reduced to small pieces in a Petri dish by means of scissors; then the DMEM medium (Gibco) having a volume of 25 ml is added, which contains antibiotics and antimycotics; the tissue is resuspended and given into a 50 ml test tube (Costar).
To the so prepared suspension for the enzymatic treatment 1 ml of a solution containing 2% collagenase of type I (Gibco) is added until a final concentration of 0.075% is reached. The suspension is incubated for 30 minutes at 37° C. in a shaker, whereby slow swinging movements should be performed.
The mixture is thoroughly stirred until a homogenic suspension is produced; afterwards 25 ml DMEM medium is added to the mixture that contains 10% FBS (HyClone, PerBio) in order to neutralize the collagenase. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed. In order to lyse the erythrocytes the pellet is resuspended in 20 ml of cold buffer solution which contains 155 mM NH 4 Cl, 10 mM KHCO 3 , 0.1 mM Na 2 EDTA. The mixture is thoroughly stirred and incubated for 3 to 5 minutes at room temperature.
The so prepared suspension is diluted with DMEM medium that contains 25 ml antibiotics and antimycotics (Gibco); subsequently the cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed. The cell supernatant is suspended in DMEM medium for washing. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The so prepared cell pellet is suspended in 25 ml DMEM-LG medium having a glucose concentration of 1 g/l (Gibco), supplemented with 20% FBS (HyClone, PerBio), one-fold solution of essential amino acids (Gibco) as well as a one-fold solution of antibiotics and antimycotics (100 units/ml penicillin, 100 microgram/ml streptomycin, 0.25 microgram/ml amphoterimycin B, Gibco).
The cell suspension is sequentially filtered by the use of filters comprising a pore size of 100 μm and 10 μm (Millipore) in order to remove cell residues and debris.
The number of purified cells is calculated in the Gorjajev chamber. The total cellular yield amounts to 10 8 /1 g of tissue. The cells are plated in 75 cm 2 flasks at 1 million/1 cm 2 each. The portion of adhering cells amounts to about 1%; the yield of mesenchymal stem cells from the decidual membrane amounts to approximately 10 6 /1 g of tissue.
After 24 hours the medium for the cells is replaced by fresh medium. Once the monolayer is reached the cells are sub-cultivated and visually evaluated in view of their morphology by the use of a phase contrast microscope; the mitosis index and the cellular generation time are calculated.
On account of the morphological analysis two major cell populations have been determined according to their phenotype. The first cell type presents itself as fusiform cells having a diameter of 15 to 35 μm with homogeneous cytoplasm, low nucleus-cytoplasm ratio, a centric nucleus consisting of 4 to 7 nucleoli. The second type comprises larger fibroblast-like, spread cells having a diameter of 90 μm with cytoplasm of diverse homogeneity; it has a low nucleus-cytoplasm ratio, a centric nucleus with 2 to 4 nucleoli. Thus, the cells to be analyzed have a morphology that is characteristic for human mesenchymal stem cells.
The mitosis index is calculated in the phase of logarithmic growth as the ratio of the number of mitosis to the total cell number. The mitosis index amounts to 29.5%. The cell generation time amounts to 29 hours.
The so obtained cells were immunophenotyped by staining with antibodies against the surface antigens CD10, CD13, CD31, CD34, CD44, CD45, CD90, CD105, CD117 (Becton Dickinson), whereby indirect fluorescence is used. The evaluation is performed by the use of a flowcytometer (Beckman Coulter). The surface marker expression corresponds to the immunophenotype of the mesenchymal stem cells: The cells are positive for CD13, CD44, CD90, CD105 and negative for CD31, CD34, CD45, CD117. The CD10 expression is moderately positive (table 1).
TABLE 1
Expression of the surface antigens on the surface of mesenchymal
stem cells from the decidual placenta membrane.
Immunophenotype of mesenchymal stem
cells from the decidual membrane
CD
%
CD10
50.30
CD13
87.00
CD31
1.50
CD34
1.30
CD44
95.90
CD45
3.40
CD90
93.70
CD105
95.50
CD117
7.00
Example 2
The chorion stroma is separated from the placenta by means of small scissors. The tissue sample of 5 g is rinsed three times with PBS (Gibco) at pH 7.2, without Ca 2+ and Mg 2+ ions. PBS (Gibco) contains a one-fold antibiotics and antimycotics solution (Gibco). The final concentration of penicillin is 100 units/ml, of streptomycin 100 microgram/ml, amphotericin B 0.25 microgram/ml.
The tissue is reduced to small pieces in 10 cm Petri dishes by means of scissors; subsequently 25 ml DMEM (Gibco) medium comprising antibiotics and antimycotics are added; afterwards, the tissue is suspended and given into a 50 ml test tube (Costar).
To the so prepared suspension for the enzymatic treatment 1 ml of a solution of 2% collagenase type IV (Gibco) is added until a final concentration of 0.075% is reached. The suspension is incubated for 30 minutes at 37° C. in a shaker with slow swinging movements.
The so prepared mixture is thoroughly stirred until a homogenic suspension is produced; afterwards 25 ml DMEM medium that contains 10% FBS (HyClone, PerBio) is added in order to neutralize the collagenase. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed. For lyses of the erythrocytes the pellet is resuspended in 20 ml of cold buffer solution which contains 155 mM NH 4 Cl, 10 mM KHCO 3 , 0.1 mM Na 2 EDTA. The mixture is thoroughly stirred and incubated for 3 to 5 minutes at room temperature.
The suspension is diluted with DMEM medium that contains antibiotics and antimycotics (Gibco) in a volume of 25 ml; afterwards the cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed. In order to wash the cell residue the latter is suspended in DMEM medium. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The so prepared cell pellet is suspended in 25 ml DMEM-LG medium having a glucose concentration of 1 mg/ml (Gibco), supplemented with 20% FBS (HyClone, PerBio), a one-fold solution of essential amino acids (Gibco) and a one-fold solution of antibiotics and antimycotics (100 units/ml penicillin, 100 microgram/ml streptomycin, 0.25 microgram/ml amphoterimycin B, Gibco).
The cell suspension is sequentially filtered by the use of filters comprising a pore size of 100 μm and 10 μm (Millipore) in order to remove cell residues and debris.
The number of purified cells is calculated by evaluation in the Gorjajev chamber. The total yield of cells amounts to 10 9 /1 g of tissue. The cells are plated in 75 cm 2 flasks at 1 million/1 cm 2 each. The portion of the adhering cells amounts to about 1%; the yield of mesenchymal stem cells from the chorion stroma amounts to approximately 10 7 /1 g of tissue.
After 24 hours the medium for the cells is replaced by fresh medium. Once the monolayer is reached the cells are sub-cultivated, visually evaluated in view of the morphology by the use of a phase contrast microscope; the mitosis index and the cell generation time are calculated.
As a result of the morphological analysis two major cell populations were identified according to their phenotypes. The first cell type presents itself as fusiform cells having a diameter of 20 to 40 μm with homogenic cytoplasm, a low nucleus-cytoplasm ratio, a centric nucleus consisting of 4 to 7 nucleoli. The second type comprises larger fibroblast-like, spread cells having a diameter of 100 μm with cytoplasm of various homogeneity; it comprises a low nucleus-cytoplasm ratio, a centric nucleus with 2 to 4 nucleoli. Thus, the cells to be analyzed have a morphology that is characteristic for human mesenchymal stem cells.
The mitosis index is calculated in the phase of logarithmic growth as the ratio of the number of mitosis to the total cell number. The mitosis index amounts to 31.8%. The cell generation time amounts to 28 hours.
The so obtained cells are immunophenotyped by staining with antibodies against the surface antigens CD10, CD13, CD31, CD34, CD44, CD45, CD90, CD105, CD117 (Becton Dickinson), whereby indirect fluorescence is used. The evaluation is performed by the use of a cytometer (Beckman Coulter). The surface marker expression corresponds to the immunophenotype of the mesenchymal stem cells. The cells are positive for CD13, CD44, CD90, CD105 and negative for CD31, CD34, CD45, CD117. The CD10 expression is moderately positive (table 2).
TABLE 2
Expression of the surface antigens on the surface of mesenchymal
stem cells from the chorion placenta stroma.
Immunophenotype of mesenchymal stem
cells from the chorion stroma
CD
%
CD10
84.40
CD13
90.90
CD31
0.20
CD34
0.30
CD44
97.60
CD45
1.50
CD90
95.30
CD105
92.70
CD117
3.90
Example 3
The amniotic membrane is separated from the placenta by means of small scissors. The tissue sample having a mass of 2 grams is rinsed three times in PBS (Gibco) at pH 7.2, without Ca 2+ and Mg 2+ ions. PBS (Gibco) contains a one-fold antibiotics or antimycotics solution (Gibco), respectively, the final concentration of penicillin is 100 units/ml, streptomycin 100 microgram/ml, amphotericin B 0.25 microgram/ml.
The tissue is reduced to small pieces in 10 cm Petri dishes by means of scissors; subsequently DMEM (Gibco) medium that contains antibiotics and antimycotics is added in a volume of 25 ml; the tissue is suspended and transferred in a 50 ml test tube (Costar).
For the enzymatic treatment to the so prepared suspension 1 ml of a solution of 1% collagenase of type I (Gibco) is added until a final concentration of 0.075% is reached. The suspension is incubated for 30 minutes at 37° C. in a shaker with slow swinging movements.
The so prepared mixture is thoroughly stirred until a homogeneous suspension is produced; then 25 ml DMEM medium that contains 10% FBS (HyClone, PerBio) is added in order to neutralize the collagenase. The cells are pelleted by centrifugation for 10 minutes by 1000 g.
The supernatant is removed. In order to lyse the erythrocytes the pellet is resuspended in 20 ml of cold buffer solution which contains 155 mM NH 4 Cl, 10 mM KHCO 3 , 0.1 mM Na 2 EDTA. The mixture is thoroughly stirred and incubated for 4 minutes at room temperature.
The so prepared suspension is diluted with DMEM medium that contains antibiotics and antimycotics (Gibco) in a volume of 25 ml. Subsequently the cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed. The cell pellet is suspended in DMEM medium for washing. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The so prepared cellular pellet is suspended in 25 ml DMEM-LG medium having a glucose content of 1 g/l (Gibco), supplemented with 20% FBS (HyClone PerBio), one-fold solution of essential amino acids (Gibco) as well as one-fold antibiotics and antimycotics solution (100 units/ml penicillin, 100 μg/ml streptomycin, 0.25 μg/ml amphotericin B (Gibco).
The cell suspension is sequentially filtered by the use of filters comprising a pore size of 100 μm and 10 μm (Millipore). The number of purified cells is evaluated by calculation in the Gorjajev chamber. The total yield of cells amounts to 10 8 /1 g of tissue. The cells are plated in 75 cm 2 flasks of 1 million/1 cm 2 each. The portion of the adhering cells amounts to about 1%; the yield of mesenchymal stem cells from the amniotic membrane amounts to approximately 10 6 /1 g of tissue.
After 24 hours the medium for the cells is replaced by fresh medium. Once the monolayer is reached the cells are sub-cultivated, visually evaluated in view of their morphology by the use of a phase contrast microscope; the mitosis index and the cell generation time are calculated.
As a result of the morphological analysis two major cell populations were determined. The first cell type presents itself as fusiform cells having a diameter of 10 to 30 μm with homogenous cytoplasm, low nucleus-cytoplasm relation, centric nucleus consisting of 4 to 7 nucleoli. The second type comprises larger fibroblast-like, spread cells having a diameter of 80 μm with cytoplasm of various homogeneity; it comprises a lower nucleus-cytoplasm relationship, a central nucleus consisting of 2 to 4 nucleoli. Thus, the cells to be analyzed show a morphology that is characteristic for human mesenchymal stem cells.
The mitosis index is calculated in the phase of logarithmic growth as the ratio of the number of mitosis to the total cell number. The mitosis index amounts to 31.6%. The cell generation time amounts to 25.7 hours.
The so obtained cells are immunophenotyped by staining with antibodies against the surface antigens CD10, CD13, CD31, CD34, CD44, CD45, CD90, CD105, CD117 (Beckton Dickinson), whereby indirect fluorescence is used. The evaluation is performed by use of a cytometer (Beckman Coulter). The surface marker expression corresponds to the immunophenotype of mesenchymal stem cells. The cells are positive for CD13, CD44, CD90, CD105, and negative for CD31, CD34, CD45, CD117. The CD10 expression is moderately positive (table 3).
TABLE 3
Expression of surface antigens at the surface of mesenchymal
stem cells from the amniotic placenta membrane.
Immunophenotype of mesenchymal stem
cells from the amniotic membrane
CD
%
CD10
58.70
CD13
93.20
CD31
1.70
CD34
1.40
CD44
98.30
CD45
0.00
CD90
92.60
CD105
96.90
CD117
1.70
Example 4
A fat tissue sample having a mass of 10 g is rinsed three times in PBS (Gibco) at pH 7.2 without the ions Ca 2+ and Mg 2+ . PBS (Gibco) contains a one-fold antibiotics and antimycotics solution (Gibco). The final concentration of penicillin is 100 units/ml, streptomycin 100 μg/ml, amphotericin B 0.25 μg/ml. The portions of compact connective tissue are removed.
Afterwards the tissue is subjected to mechanic fragmentation using medical scissors in 10 cm culture dishes (Costar), until a fine-dispersed mass is produced. It is transferred into two 50 ml test tubes having a cone-shaped bottom (Costar). Afterwards each sample is suspended in 25 ml DMEM medium that contains antibiotics and antimycotics.
Afterwards the enzymatic treatment is performed: to the so prepared suspension 1 ml of a solution of 2% collagenase of the type Gibco in the PBS buffer solution without Ca and Mg 2+ is added until a final enzyme concentration of 0.075% is reached. The suspension is incubated for 30 minutes at 37° C. at slow swinging movements.
The so prepared mixture is thoroughly mixed; then an equivalent DMEM volume is added that contains 10% FBS, antibiotics and antimycotics. The centrifugation lasts 10 minutes at 1000 g. The supernatant and the fat drops are removed. The pellets are pooled and suspended in 10 ml of cold lysine buffer solution (+4° C.) for 10 minutes, which contains 155 mM NH 4 Cl, 10 mM KHCO 3 , 0.1 mM Na 2 EDTA. The mixture is thoroughly stirred and incubated for 3 to 5 minutes at room temperature.
Subsequently, 10 ml DMEM medium which contains antibiotics and antimycotics are added to the cell suspension. The cells are pelleted by centrifugation for 10 minutes at 1000 g.
The supernatant is removed and rinsed. The cell pellet is resuspended in 30 ml DMEM medium that contains antibiotics and antimycotics, and is centrifuged for 10 minutes at 1000 g.
The so obtained pellet is resuspended in 25 ml DMEM medium that contains antibiotics and antimycotics.
The so prepared cell suspension is filtered by the use of a filter comprising a pore size of 100 μm and is centrifuged for 10 minutes at 300 g. The pellet is resuspended in DMEM medium that is supplemented with antibiotics and antimycotics, 10% FBS and a one-fold solution of non-essential amino acids (Gibco) in a volume of 25 ml. The suspension is filtered by the use of a filter comprising a pore size of 10 μm.
In doing so, a homogenous cell fraction is produced that is free of cellular debris and blood cells.
The so prepared cell suspension is evaluated by calculation in the Gorjajev chamber and plated in 75 cm 2 flasks (10 6 cells/cm 2 ). The portion of adhering cells amounts to about 1% to 1.5%; the yield of mesenchymal stem cells which could be obtained from 1 g of fat tissue amounts to about 1.5-3×10 4 cells.
After 24 hours the medium is replaced by DMEM that contains antibiotics (100 units/ml penicillin, 100 μg/ml streptomycin (Gibco), 10% FBS and a one-fold solution of non-essential amino acids (Gibco).
Once the monolayer is reached, the cells are sub-cultivated, visually evaluated in view of the morphology by the use of a phase contrast microscope; the mitosis index and the cell generation time are calculated.
After the obtainment of cell fractions as a result of the morphological analysis two sub-populations were determined. The first cell type presents itself as a sub-population of fusiform cells having a diameter of 10 to 15 μm with exactly adjusted nucleus and homogenous cytoplasm. The second type is characterized by round cells with a flat cytoplasmatic outgrowth elongated on one side. The cell size amounts to 40 μm; a dark nucleus is observable which is displaced to the side, and a heterogenous cytoplasm. Also an increased granulation in the area of the nucleus is observable.
The mitosis index and the cell generation time is calculated in the phase of logarithmic growth. The ratio of the portion of cells being in mitosis to the total cell number amounts to 34%. The doubling time is about 54 to 62 hours.
The so obtained cells are immunophenotyped by the use of indirect fluorescence. By the use of a cytometer (Beckman Coulter) a high expression status of the following antigens could be determined: CD10 (CALLA), CD13 (APN), CD44 (hyaluronic acid receptor), CD90 (Thy-1), CD105 (endoglin) (Becton Dickinson). Furthermore, the lacking expression of the markers of hematopoietic cells—CD34, CD45 and CD117 (Becton Dickinson)—(table 4) was determined. The results of the determination of the immunophenotype prove that the population of the obtained cells corresponds to mesenchymal stem cells in view of their surface antigen expression.
TABLE 4
Surface antigen expression on the surface of
mesenchymal stem cells from fat tissue
Immunophenotype of mesenchymal stem cells from fat tissue
CD
%
CD10
68.08
CD13
96.53
CD34
4.38
CD44
93.08
CD45
3.28
CD90
98.36
CD105
90.18
CD117
2.30 | The invention relates to the field of cell biology. In detail it relates to the obtainment of mesenchymal stem cells from human tissue. This invention might be applicable in healing within the frame of the treatment of several diseases.
Due to the invention it will be possible to obtain mesenchymal stem cells from human tissue with high homogeneity of the cell suspension, since the used method for obtaining mesenchymal stem cells from human tissue comprises the crushing and enzymatical treatment of the tissue with collagenase solution in Eagle medium in the Dulbecco modification, removal of erythrocytes by the aid of the lysis solution and subsequent filtration of the prepared suspension; as human tissue fat tissue or decidual or amniotic placenta membrane or chorion placenta stroma is used, whereas the filtration is performed sequentially by the use of filters comprising a pore size of 100 μm and 10 μm. In the enzymatical treatment of the fat tissue, of the decidual or amniotic placenta membrane collagenase of the type I is used, and in the enzymatical treatment of the chorion placenta stroma collagenase of the type IV is used. | 2 |
CROSS-REFERENCES
U.S. Paten Documents
[0001] [0001] 5,906,806 May 1999 Clark 60/649 5,937,652 August 1999 Abdelmalek 60/648 6,047,547 April 2000 Heaf 60/618 6,116,169 September 2000 Miyoshi, et al 110/216 6,196,000 March 2001 Fassbender 60/649 6,282,901 September 2001 Marin, et al. 60/649
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process for power generation, which is both environmentally sound and cost-effective. More specifically, the invention relates to a process of burning any combustible material for efficient power generation, elimination of air pollutants and carbon dioxide emissions, and recovery of liquid nitrogen dioxide, liquid sulfur dioxide, and liquid carbon dioxide.
[0004] 2. Description of the Prior Art
[0005] A conventional power plant consisting of a combustion furnace, a steam boiler, steam turbines, and a dust collector has been implemented for power generation and steam production for several decades. Conventional power plants, particularly for coal-fired plants, emit a huge amount of nitrogen oxides, sulfur dioxide, carbon monoxide, particulate matters, heavy metals, and incomplete combustion products. Since air pollution control requirements become more stringent from time to time, power plants must be equipped with more sophisticated and expensive pollution control systems to meet regulatory emission limits. For sulfur oxides emission control, a flue gas desulfurization system or a fluidized bed combustion furnace is widely used. For nitrogen oxides emission control, power plants have implemented a combustion flue gas recirculation for staged combustion with steam or water injection, low NOx burners, selective catalytic reduction systems, non-selective catalytic systems, or any combination thereof to meet the emission limits.
[0006] Since the 1980's, the integrated gasification combined cycle (IGCC) concept has been explored extensively. IGCC uses an oxygen stream for coal gasification and produces a gaseous stream consisting of methane, hydrogen sulfide, carbon monoxide, ammonia, etc. The gaseous stream passes through a sulfur removal system such as a Claus plant before burning in a gas turbine. In addition to requiring an expensive sulfur removal system, an IGCC plant must implement a nitrogen oxides removal system in order to meet regulatory requirements.
[0007] Since the Kyoto Accord for reduction of carbon dioxide, which is a greenhouse gas that causes global warming and associated climatic changes, coal-fired power plants have been extensively scrutinized. Although a coal-fired power plant is still the most cost-effective in power generation, its carbon dioxide emission is more than two times that of a natural gas fired plant. An MEA scrubbing system using monoethanolamine as absorbing agent has been implemented to recover carbon dioxide from combustion flue gases, but it is still not cost-effective. To enhance carbon dioxide recovery, oxygen is increasingly proposed as a replacement of air in fuel burning to reduce the volume of combustion flue gases and to increase the concentration of carbon dioxide in combustion flue gases.
[0008] U.S. Pat. No. 5,906,806 issued to Clark proposes to burn fuel using oxygen, water, and a recirculated combustion stream from a baghouse in two combustion furnaces. For additional air pollution control, Clark's proposal requires several expensive control systems, which include an electron beam reactor, an ozone oxidation chamber, and an electrostatic precipitator with catalytic reactor. In addition, the combustion product discharged to the atmosphere still contains some incomplete combustion products and nitrogen related products and excess oxygen discharged with combustion flue gases reduce utilization of oxygen generated by an air separation unit.
[0009] U.S. Pat. No. 6,196,000 issued to Fassbender proposes to burn fuel using oxygen and liquid carbon dioxide recovered from combustion process. For enhancing thermodynamic efficiency and carbon dioxide recovery, Fassbender proposes to operate an elevated pressure power plant. All operating units including a reaction chamber, a combustion chamber, a catalyst chamber, a hydrocone, heat exchanges, and condensers are under extremely high pressure, ranging from 300 to 500 psia. A pressurized vessel requires additional power to operate and become a safety concern. In addition, the pressurized power plant still vents to the atmosphere a combustion flue gas stream containing some air pollutants and oxygen.
BRIEF SUMMARY OF THE INVENTION
[0010] The invention is an integrated combustion process for efficient power generation, recovery of waste heat and byproduct, and elimination of air pollution. A combustion furnace, air separation units, a steam boiler with an economizer, a dust and acid gas removal system, several condensers, and adsorption refrigeration units are integrated with two combustion flue gas recirculation loops to enhance steam product and to prevent combustion flue gases from being discharged into the atmosphere.
[0011] When oxygen is used instead of air for fuel combustion, the temperature of combustion products is extremely high. For combustion temperature control, the first combustion flue gas recirculation loop is implemented to recirculate part of the combustion gas stream from the economizer to the combustion furnace. How much of the combustion flue gas stream from the economizer to be recirculated back to the combustion furnace greatly depends on the chemical composition and heat content of fuel.
[0012] The combustion flue gas stream from the economizer, which is not recirculated back to the combustion furnace, passes through an oxygen-enriched stream heater for additional waste heat recovery, a fly ash and acid gas removal system, and several byproduct condensation units. After leaving the carbon dioxide condenser, it mixes with an oxygen-enriched stream from the air separation unit and flows back to the combustion furnace. The purpose of the second combustion flue gas recirculation loop is to eliminate any incomplete combustion products in the combustion furnace and reuse oxygen present in the combustion flue gas stream. Therefore, a combustion process designed according to the invention does not discharge combustion flue gases and air pollutants to the atmosphere. The nitrogen-enriched stream from the air separation unit is used in the condensers for byproduct recovery.
[0013] Adsorption refrigeration units are integrated with the process to recover and convert waste steam from steam turbines to cooling. Cooling generated by adsorption refrigeration units is used for enhancing condensing processes as well as providing extra cooling for industrial, commercial, or residential uses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The integrated nature of the present invention's steps is better understood by reviewing the detailed description of the invention in conjunction with the accompanying drawings, in which:
[0015] [0015]FIG. 1 is a block flow diagram of the present invention showing relationship between each combustion flue gas stream, oxygen-enriched stream, and nitrogen-enriched stream;
[0016] [0016]FIG. 2 is a table listing coal chemical composition, combustion products, boiling and melting temperatures, and heat of vaporization; and
[0017] [0017]FIG. 3 is a schematic representation of an integrated power plant incorporating the present invention to achieve no discharge of combustion flue gas and air pollutants.
DETAILED DESCRIPTION OF THE INVENTION
[0018] [0018]FIG. 1 shows the objects of the present invention that is a process for combustion fuel or any combustible material with an oxygen-enriched stream for power generation without any discharge of combustion flue gas and air pollutants to the atmosphere. FIG. 2 graphically depicts the relationship among various unit operations and various streams.
[0019] The heat content with chemical composition of fuel determines theoretical oxygen requirement. One pound of coal with heat content and chemical composition shown in FIG. 2 needs about 2.4 pounds of oxygen compared to 4.0 pounds of oxygen needed for one pound of methane. During a startup mode, when fuel stream 62 burns with oxygen-enriched stream 44 in combustion furnace 11 , liquid carbon dioxide stream or water stream 63 is injected into combustion furnace 11 for combustion temperature control until the process reaches a normal mode of operation.
[0020] To maintain the combustion temperature between 2000 and 2500.degree.F. inside a refractory-wall combustion furnace, one pound of coal, with heat content and chemical composition shown in FIG. 2, requires between 8 and 12 pounds of liquid carbon dioxide or between 4 and 5 pounds of water. For one pound of methane, it needs between 18 and 24 pounds of liquid carbon dioxide or between 7.5 and 9.5 pounds of water. For a water-wall combustion furnace, it needs a less amount of liquid carbon dioxide or water for combustion temperature control because water flowing through water-wall tubes reduces combustion temperature. Combustion furnace 11 is a combustion device commonly known by those of ordinary skill in the art. Bottom ash from combustion chamber 11 drops into bottom ash collection tank 12 , which is equipped with water seals to prevent air from entering combustion chamber 11 . Sludge steam 59 is drawn from bottom ash collection tank 12 to an ash management and disposal system
[0021] Combustion flue gas stream 27 with a temperature between 2000 and 2500.degree.F. from combustion furnace 11 enters steam boiler 13 to convert water/steam stream 54 from economizer 15 to superheated steam 50 used in steam turbine 14 for electricity generation. Combustion flue gas stream 28 with a temperature between 800 and 1000.degree.F from steam boiler 13 enters economizer 15 to preheat water/steam stream 53 from de-aerator 24 . Combustion flue gas stream 29 with a temperature between 600 and 800.degree.F from economizer 15 enters flue gas manifold 16 , where it splits into combustion flue gas stream 30 and combustion flue gas stream 31 . Steam boiler 13 and economizer 15 are indirect heat exchanges commonly known by those of ordinary skill in the art.
[0022] Combustion flue gas stream 30 is recirculated back to combustion furnace 11 , through flue gas recirculation pump 11 A, for combustion temperature control. Combustion flue gas stream 31 enters oxygen-enriched stream heater 17 . The ratio of combustion flue gas stream 30 to combustion flue gas stream 31 depends on fuel involved in combustion. When the process reaches its normal mode of operation, the ratio for coal discussed in FIG. 2 is between 4 and 7 compared to a ratio between 5 and 8.5 for methane. The ratio of combustion flue gas stream 30 to combustion flue gas stream 31 is significantly lower for a water-wall combustion furnace.
[0023] In a normal operation mode, the volume of combustion flue gas stream 31 is less than 30 percent of that generated by a conventional power plant using air stream for combustion. Oxygen-enriched stream heater 17 is an indirect heat exchanger, which is commonly known by those of ordinary skill in the art. Inside oxygen-enriched stream heater 17 , combustion flue gas stream 31 preheats oxygen-enriched stream 43 from water vapor condenser 18 .
[0024] Combustion flue gas stream 32 with a temperature between 250 and 450.degree.F enters dust and acid gas removal unit 25 for fly ash and acid gas removal. Dust and acid gas removal unit 25 is a baghouse, a dry or wet cyclone, a dry or wet multiple-cyclone collector, a venturi scrubber, a packed bed absorber, an electrostatic precipitator, or any combination of thereof, which is commonly known by those of ordinary skill in the art. Dust and acid gas removal unit 25 is equipped with water seals to prevent air from entering combustion flue gas streams. For fuel containing chloride and other halogen, a multiple-cyclone collector with a packed bed absorber is preferably selected to remove fly ash, hydrogen chloride, sulfuric acid, and other hydrogen halides. If a baghouse is preferably implemented, carbon dioxide is used instead of air for bag cleaning to prevent air from entering combustion flue gas streams 32 and 33 . Fly ash and other acidic material collected by dust and acid gas removal unit 25 drop into fly ash collection tank 26 and sludge stream 60 is discharged to an ash management and disposal system.
[0025] Combustion flue gas stream 33 from dust and acid gas removal unit 25 enters water vapor condenser 18 for removal of water vapor, remaining fly ash, and any condensable material found in combustion flue gas stream 33 . Water vapor condenser 21 is an indirect heat exchanger, which is commonly known by those of ordinary skill in the art. Water collected from water vapor condenser 18 is preferably used for fly ash and bottom ash collection tanks. Inside water vapor condenser 18 , oxygen-enriched stream 42 from nitrogen dioxide condenser 19 serves as a main cooling stream. Nitrogen-enriched stream 48 from nitrogen dioxide condenser 19 as well as coolant stream 55 from adsorption refrigeration unit 23 is arranged in the process to provide sufficient cooling for water vapor condenser 18 .
[0026] Combustion flue gas stream 34 with a temperature between 90 and 180.degree.F. from water collection tank 18 A, which is connected to vapor condenser 18 , enters nitrogen dioxide condenser 19 for removal of nitrogen dioxide and any condensable material found in combustion flue gas stream 34 . Nitrogen dioxide condenser 21 is an indirect heat exchanger, which is commonly known by those of ordinary skill in the art. Inside nitrogen dioxide condenser 19 , oxygen-enriched stream 41 from sulfur dioxide condenser 20 serves as a main cooling stream. Nitrogen-enriched stream 47 from sulfur dioxide condenser 20 is arranged to provide sufficient cooling for nitrogen dioxide condenser 19 . Liquid nitrogen dioxide is a process byproduct, which could be used for production of nitric acid, nitrating or oxidizing agent, catalyst, rocket fuels, or polymerization inhibitor for acrylates.
[0027] Combustion flue gas stream 35 with a temperature between 20 and 60.degree.F. from liquid nitrogen dioxide collection tank 19 A, which is connected to nitrogen dioxide condenser 19 , enters sulfur dioxide condenser 20 for removal of sulfur dioxide and any condensable material found in combustion flue gas stream 35 . Sulfur dioxide condenser 20 is an indirect heat exchanger, which is commonly known by those of ordinary skill in the art. Inside sulfur dioxide condenser 20 , oxygen-enriched stream 40 from oxygen-enriched stream manifold 21 C serves as a main cooling stream. Nitrogen-enriched stream 46 from carbon dioxide condenser 21 is arranged to provide sufficient cooling for sulfur dioxide condenser 20 . Liquid sulfur dioxide is a process byproduct, which could be used for production of sulfuric acid, sulfite paper pulp, sulfonation of oil, antioxidant, reducing agent, and many other uses.
[0028] After leaving liquid sulfur dioxide collection tank 20 A, which is connected to sulfur dioxide condenser 20 , combustion flue gas stream 36 with a temperature between −60 and 10.degree.F. is pressurized by flue gas recirculation fan 211 B to a pressure above 77 psia and enters carbon dioxide condenser 21 for removal of carbon dioxide and any condensable material found in combustion flue gas stream 36 . Carbon dioxide condenser 21 is an indirect heat exchanger, which is commonly known by those of ordinary skill in the art. Inside carbon dioxide condenser 21 , both oxygen-enriched stream 38 and nitrogen-enriched stream 45 from air separation unit 22 serve as cooling streams. Liquid carbon dioxide is a major process byproduct, which could be used for refrigeration, carbonated beverages, aerosal propellant, fire extinguishing, fracturing and acidizing of oil wells, and many other uses.
[0029] After liquid carbon dioxide being removed, combustion flue gas stream 37 from liquid carbon dioxide collection tank 21 A, which is connected to carbon dioxide condenser 21 , is a small stream containing a small amount of carbon dioxide, carbon monoxide, nitric oxide, methane, ammonia, and oxygen. It enters oxygen-enriched stream manifold 21 C and combines with oxygen-enriched stream 39 from carbon dioxide condenser 21 . The purpose of this (second) combustion flue gas recirculation loop is to eliminate the discharge of combustion flue gases and air pollution into the atmosphere and fully utilize oxygen produced by air separation unit 22 . The combined stream, oxygen-enriched stream 40 , passes through sulfur dioxide condenser 20 , nitrogen dioxide condenser 19 , water vapor condenser 18 , and oxygen-enriched stream heater 17 . Then, it enters combustion furnace through forced draft fan 11 B to begin another combustion cycle.
[0030] Preferably, this invention incorporates adsorption refrigeration unit 23 , which is commonly known by those of ordinary skill in the art, to recover waste steam stream 51 from steam turbine 14 for cooling, which is used for water vapor condenser 18 , air separation unit 22 , and other industrial, commercial, or residential use. For reducing energy consumption by air separation unit 22 in air separation process, coolant streams 57 and 58 are circulated between adsorption refrigeration unit 23 and air separation unit 22 . To provide sufficient cooling for water vapor condenser 18 , coolant streams 55 and 56 are circulated between adsorption refrigeration unit 23 and water vapor condenser 18 . | The invention relates to an integrated power plant, which burns fuel using an oxygen-enriched stream in a combustion furnace and converts emissions of air pollutants and carbon dioxide into byproducts. The combustion flue gas stream, after leaving an economizer of a steam generation system, splits into stream A and stream B. Stream A recirculates back to the combustion furnace through the first flue gas recirculation fan for combustion temperature control. Stream B, after passing through a dust collector for fly ash removal, a series of condensers for byproduct recovery, and the second flue gas recirculation fan, mixes with an oxygen-enriched stream from an air separation unit and flows back to the combustion furnace. The plant does not need an exhaust stack and does not discharge combustion flue gases into the atmosphere. | 8 |
TECHNICAL FIELD
The subject concept relates generally to a rest for use to hold a weapon, such as a rifle, during target practice and the like and more specifically relates to a unitary, stable rifle rest that is easy to use, sturdy in construction and has a limited number of moving parts.
BACKGROUND
Various known rifle supports have numerous moving parts and are made of light weight metal materials and/or plastic materials. Other known rifle supports do not allow the user to hold the rifle against his shoulder during use since the butt end is secured on the support mechanism. Still other known rifle support mechanisms use a single point of contact at the end thereof where the butt of the rifle rests. This single point of contact does not provide much resistance to movement of the support mechanism during shooting of the rifle. It is desirable for the user to be able to rest the rifle on the rifle rest while holding the rifle against his shoulder in a normal manner and fire the rifle at a target or the like with great accuracy and to be able to fire repeated rounds at the target without having to take a lot of time and effort to re-aim the rifle. Likewise it is desirable to readily pick up the rifle rest, without major effort, and move it to a different location.
SUMMARY OF THE INVENTION
According to the present concept, a rifle rest is provided that is made substantially of a unitary design having limited moving parts and is a mobile design that can be moved from place to place without requiring major physical efforts. The subject concept has a front portion, a mid portion, and a rear portion each rigidly attached to each other. The front portion has a bag receiving portion spaced upward from a bottom thereof a predetermined distance and positioned generally central of the front portion. An adjustment mechanism is disposed on outer portions of the front portion and adapted to permit vertical adjustment of the front portion relative to the surface that it rests upon. The mid portion has a width of a predetermined size and shape. The rear portion has a bag receiving portion spaced upward from a bottom thereof at a predetermined distance less than the predetermined distance of the bag receiving portion of the front portion. The rear portion has a bottom edge portion having a predetermined width extending parallel to the front portion and being of a width at least the width of the mid portion thereof.
The construction of the subject rifle rest provides a more stable rifle rest having limited movement during target practice and is easily moved from one place to another. Since the rifle rest is made of a unitary construction, there are no moving parts to create instability during use. Furthermore, once an elevational change has been made with the adjustment mechanism, the adjustment mechanism is also effective to make minor adjustments from side to side to ensure that the bottom edge portion of the rear portion remains in full contact with the surface on which it is resting.
Other objects, features, and advantages of the subject concept will become more apparent from the following detailed description of the preferred embodiments and certain modification thereof when taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a photographic perspective view of a working model of the subject concept with pre-purchased sand bags in place;
FIG. 2 is a pre-shortened top view of the rifle rest illustrated in FIG. 1 ;
FIG. 3 is a front view of the rifle rest of FIG. 2 ; and
FIG. 4 is a pre-shortened side view of the rifle rest of FIG. 2 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a rifle rest 10 is disclosed having a unitary frame 12 and an adjustment mechanism 14 disposed thereon. The unitary frame 12 is composed of a front portion 15 , a middle portion 16 and an end portion 17 .
Referring to FIGS. 2 , 3 and 4 in conjunction with FIG. 1 , the front portion 15 defines a first member 18 having a predetermined cross-sectional shape. In the subject arrangement, the predetermined cross-sectional shape is a box shape of a predetermined cross-sectional size. The first member 18 has first and second sides 19 , 20 and a predetermined length ‘L’. In the subject arrangement the predetermined length ‘L’ is approximately 305 mm (12 inches).
The first member 18 has opposed first and second end portions 21 , 22 with a threaded passage 23 disposed in the first end portion 21 through a first square insert 25 and another threaded passage 24 disposed in the second end portion 22 through a second square insert 26 . The first and second square inserts 25 , 26 are disposed generally adjacent the respective ends of the first member 18 and secured thereto by, for example, welding. It is recognized that the first and second square inserts could be secured to the first member 18 in various known ways without departing from the essence of the subject design.
A second member 28 has first and second ends 30 , 32 and the first end 30 thereof is solidly secured to the first member 18 by, for example, welding. The second member 28 has the same cross-sectional shape and size as that of the first member 18 . The first end 30 of the second member 28 is secured to the first side 19 of the first member 18 at the mid-point thereof and the second member 28 extends generally perpendicular therefrom and in a generally vertical direction for a predetermined height ‘L1’.
A bag receiving portion 34 is secured to the second end 32 of the second member 28 by, for example, welding and adapted to receive a pre-purchased sand bag 36 (shown in FIG. 1 ). The sand bag 36 is shown for illustrative purposes only, it does not constituent any part of the subject design. It is recognized that other sand bags could be used without departing from the essence of the subject design. The bag receiving portion 34 includes a u-shaped member 38 having a surface 39 and first and second flanges 40 , 42 formed thereon. The u-shaped member 38 has a width ‘W’ that is substantially the same size as the cross-sectional size and shape of the second member 28 and a length ‘L2’ that is generally one half of the length of the first member 18 . The length ‘L2’ of the u-shaped member 38 is parallel with the length ‘L’ of the first member 18 and has the flanges 40 , 42 defined at opposite ends of the length ‘L2’.
The middle portion 16 includes a third member 50 having first and second ends 52 , 54 . The cross-sectional size and shape of the single member 50 of the middle section is substantially the same as the cross-section of first and second members 18 , 28 of the front portion 15 . The first end 52 of the third member 50 is secured to the second side 20 of the first member 18 of the front portion 15 by, for example, welding and extends generally perpendicular therefrom in a generally horizontal direction when laid on a shooting surface (not shown).
The rear portion 17 includes a fourth member 58 having first and second ends 60 , 62 , first, second, and third sides 64 , 66 , 67 and a bottom edge portion 68 . The first side 64 of the fourth member 58 of the rear portion 17 is secured to the second end 54 of the single member 50 of the middle portion 16 by, for example, welding. The fourth member 58 herein has a cross-sectional size and shape substantially the same as that of the first and second members 18 , 28 of the front portion 15 and the third member 50 of the middle portion 16 . The fourth member 58 of the rear portion 17 is oriented parallel to the orientation of the first member 18 of the front portion 15 .
The fourth member 58 of the rear portion 17 has a predetermined length ‘L3’ that is generally one-half of the length ‘L’ of the first member 18 of the front portion 15 . It is recognized that the ratio of the length ‘L3’ of the fourth member 58 of the rear portion 17 and the length ‘L’ of the first member 18 of the front portion 15 could be within the range of 1 to 6. However, a ratio of 1-4 could be used while a ratio of 1-2 is preferable.
The bottom edge portion 68 of the fourth member 58 of the rear portion 17 includes a bottom surface 70 of the fourth member 58 and an edge 72 defined by the bottom surface 70 and the third side 67 of the fourth member 58 .
The rear portion 17 also includes a bag receiving portion 78 disposed on the second side 66 of the fourth member 58 thereof and being adapted to receive a pre-purchased sand bag. It is recognized that various other type of sand bags could be used without departing from the essence of the subject design. The bag receiving portion 78 includes a three sided rectangular pan 82 secured thereto by, for example, welding. The three sided rectangular pan 82 is disposed thereon so that the open side of the pan faces towards of the front portion 15 and is located centrally along a vertical reference plane 84 defined along the middle of the middle portion 16 .
In the subject design, the three sided rectangular pan 82 is disposed on the second side 66 of the first member 58 of the rear portion 17 and the predetermined height ‘L1’ defined with respect to the position of the surface of the pan 82 and the position of the surface of u-shaped member 38 of the front portion 15 . In the subject arrangement, the predetermined height ‘L1’ is approximately 127 mm (5 inches). It is recognized that the subject predetermine height could be varied depending on the size and shape of the respective sand bags 36 , 80 used. In the subject design, the predetermined height ‘L1’ has approximately a 1 to 2.4 size relationship relative to the predetermined width ‘L’.
The adjustment mechanism 14 includes first and second adjusting screws 86 , 88 with associated first and second lock nuts 90 , 92 . The first lock nut 90 is threaded onto the first adjusting screw 86 and the first adjusting screw 86 is threadably disposed within the threaded passage 23 of the first member 18 of the front portion 15 . Likewise, the second lock nut 92 is threaded onto the second adjusting screw 88 and the second adjusting screw 88 is threadably disposed within the threaded passage 24 of the first member 18 of the front portion 15 . The first and second adjusting screws 86 , 88 can be threaded up or down and locked in the chosen position with the respective lock nuts 90 , 92 . It is recognized that other types of adjusting mechanisms could be used without departing from the essence of the subject design.
INDUSTRIAL APPLICABILITY
The subject rifle rest 10 provides a solid rest for a rifle during target practice and the like and does not readily move around during shooting of the rifle. It also provides the ability for the shooter to hold the rifle in a normal position while the rifle is cradled in the rifle rest. The unitary frame 12 acts to ensure that there is no flexing of the bag receiving portion 34 on the front portion 15 relative to the bag receiving portion 78 on the rear portion 17 . Likewise, the second member 28 of the front portion 15 does not permit any relative movement between the first member 18 and the bag receiving portion 34 of the front portion 15 .
Since the bag receiving portion 78 on the rear portion 17 is firmly secured to the fourth member 58 of the rear portion 17 , no relative movement is permitted therebetween.
During use, the shooter positions his body adjacent the rifle rest 10 and positions the shank of the rifle on the sand bag 36 of the front portion 15 and rests the butt of the rifle against his shoulder and the rear bag 80 of the rear portion 17 . If the target is not in sight of the rifle sights, the shooter raises or lowers the front portion 15 as needed by turning of the respective first and second adjustments screws 86 , 88 . Once the front portion 15 of the rifle rest 10 has been properly adjusted with respect to the target, the shooter visually checks the position of the bottom edge portion 68 with respect to the surface that it is resting upon. If the bottom edge portion 68 , which can either be the bottom surface 70 or the edge 72 defined by the bottom surface 70 and the third side 67 , is not in contact with the surface that it rests upon across it's full width, the shooter adjusts the appropriate one of the adjusting screws 86 , 88 until full contact is achieved. This full contact of the bottom edge portion 68 works to ensure that the rifle rest 10 is stable and does not allow adverse movement during shooting of the rifle.
Other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with the underlying concept. It is to be understood, therefore, that the subject design may be practice otherwise than as specifically set forth above. | A rifle rest structure is adapted to receive first and second sand bags and operative to place a rifle thereon for target practice or the like. The rifle rest has a unitary frame construction including a front portion that supports the front of a rifle, a rear portion that supports the rear of the rifle, and a middle portion that rigidly interconnects the front and rear portions. The front portion has a length that is longer than a parallel length of the rear portion. The length of the front portion is in the range of six times longer than the parallel rear portion. The rifle rest further includes an adjusting mechanism that is operative to adjust the elevation of the front portion relative to the rear portion. The subject arrangement provides good stability for the rifle during use. | 5 |
RELATED APPLICATION DATA
[0001] This application is a divisional of U.S. Ser. No. 10/104,499, filed on March 21, 2002.
STATEMENT OF GOVERNMENT RIGHTS
[[0002]] This invention was made with the U.S. Government support under Grant Number DAMD17-96-1-6006, awarded by the Army Medical Research and Materiel Command. The U.S. Government may have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] The present disclosure is related to the field of artificial valves, and more specifically to an implantable, sutureless valve graft comprising a biomaterial. The disclosure is further related to a method for suturelessly bonding a biomaterial to a bioprosthetic frame.
[0004] Prosthetic stents and valves have been described in the prior art. Stents have been used with success to overcome the problems of restenosis or re-narrowing of a vessel wall. Valves are exemplified by U.S. Pat. No. 5,258,023 (to Roger), in which a prosthetic valve is taught that is constructed of synthetic materials.
[0005] However, the use of such devices is often associated with thrombosis and other complications. Additionally, prosthetic devices implanted in vascular vessels can exacerbate underlying atherosclerosis.
[0006] Research has focused on trying to incorporate artificial materials or biocompatible materials as bioprosthesis coverings to reduce the untoward effects of metallic device implantation. Such complications include intimal hyperplasia, thrombosis and lack of native tissue incorporation.
[0007] Synthetic materials for stent coverings vary widely, e.g., synthetic materials such as Gore-Tex®, polytetrafluoroethylene (PTFE), and a resorbable yarn fabric (U.S. Pat. No. 5,697,969 to Schmitt et al.). Synthetic materials generally are not preferred substrates for cell growth.
[0008] Biomaterials and biocompatible materials also have been utilized in prostheses. Such attempts include a collagen-coated stent, taught in U.S. Pat. No. 6,187,039 (to Hiles et al.). As well, elastin has been identified as a candidate biomaterial for covering a stent (U.S. Pat. No. 5,990,379 (to Gregory)).
[0009] In contrast to synthetic materials, collagen-rich biomaterials are believed to enhance cell repopulation and therefore reduce the negative effects of metallic stents. It is believed that small intestinal submucosa (SIS) is particularly effective in this regard.
[0010] Bioprosthetic valves combining synthetic and biological materials have also been studied. For example, U.S. Pat. No. 5,824,06 (to Lemole); U.S. Pat. No. 6,350,282 (to Eberhardt); and U.S. Pat. No. 5,928,281 (to Huynh) teach bioprosthetic heart valves that may employ an aortic valve (comprising animal or patient tissue) sutured to an artificial valve frame.
[0011] Some of the above-discussed coverings, while used to prevent untoward effects, actually exacerbate the effects to some extent. Accordingly, it is desirable to employ a native biomaterial or a biocompatible material to reduce post-procedural complications.
[0012] A mechanically hardier valve graft device is required in certain implantation sites, such as cardiac, aortic, or other cardiovascular locations. In order to produce a sturdier bioprosthesis, a plurality of layers of biomaterial may be used. Suturing is a poor technique for joining multiple layers of biomaterial. While suturing is adequate to join the biomaterial sheets to the metallic frame, the frame-sutured multiple sheets are not joined on their major surfaces and are therefore subject to leakage between the layers. Suturing of the major surfaces of the biomaterial layers introduces holes into the major surfaces, increasing the risk of conduit fluid leaking through or a tear forming in one of the surfaces.
[0013] Heretofore, biomaterials have been attached to bioprosthetic frames, e.g., stents and valves, using conventional suturing techniques. As well, the primary methods available for securing prostheses to tissue (or tissue to tissue) involved the use of sutures or staples. However, this approach is disadvantageous from manufacturing and implantation perspectives.
[0014] Suturing is time-consuming and labor-intensive. For example, suturing a sheet of biomaterial over a stent frame typically is an operator-dependent process that can take up to two hours for trained personnel. Because suturing is manually performed, there are concerns relating to manufacturing uniformity and product reliability. As well, suturing entails repeatedly puncturing the biomaterial, creating numerous tiny holes that can weaken the biomaterial and potentially lead to leakage and infection after the graft device has been installed.
[0015] Moreover, the presence of suture material can enhance the foreign body response by the host patient, leading to a narrowing of the tubular vessel in which the graft is implanted.
[0016] A recent attempt to provide a “sutureless” heart valve prosthesis, U.S. Pat. No. 6,287,339 (to Vazquez, et al.), while providing a valve device to be attached to patient tissue without the use of sutures, nevertheless continues to require sutures to secure the active portion of the prosthesis to its abutment structure.
[0017] Biocompatible adhesive compounds and photochemical cross-linking agents have been investigated as alternatives to suturing. For example, fibrin glue, a fibrinogen polymer polymerized with thrombin, has been used as a tissue sealant and hemostatic agent.
[0018] Bioadhesives generally produce rigid, inflexible bond regions that can lead to local biomaterial tears and failure of the graft device. In addition, some bioadhesives and photochemical cross-linking agents carry risk of acute and chronic toxicity and bio-incompatibility.
[0019] The invention will become more readily apparent from the following detailed description, which proceeds with reference to the drawings, in which:
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIG. 1 is a top view of a valve graft according to the present disclosure.
[0021] FIGS. 2-3 are perspective side and axial views, respectively, of the
[0022] FIG. 4 is a top view of one embodiment of a valve frame before and after a distorting force is applied to distort the frame into a flexed state.
[0023] FIG. 5 is a top view of the flexed-state valve frame placed on a sheet of biomaterial.
[0024] FIG. 6 is a cross-sectional side view of the valve frame and biomaterial taken through line 6 - 6 in FIG. 5 .
[0025] FIG. 7 is a view of the cross-section of FIG. 6 , showing folding of the edge of the biomaterial sheet over the wire frame.
[0026] FIG. 8 is a view of the cross-section of FIGS. 6-7 , showing one embodiment of sutureless bonding of the edge of the biomaterial sheet to the first major surface of the sheet at a first bonding locus.
[0027] FIG. 9 is a cutaway perspective view diagram of one embodiment of a method for implanting a valve graft employing a catheter to introduce the folded valve graft to an implantation site in a patient's tubular vessel.
[0028] FIG. 10 is a cutaway perspective view diagram showing a valve graft introduced into a tubular vessel by a catheter.
[0029] FIG. 11 is an axial view down the tubular vessel of FIGS. 9-10 from reference line 11 - 11 , showing the implanted valve graft.
[0030] FIGS. 12-13 are cutaway perspective views of the implanted valve graft of FIGS. 10-11 , showing unidirectional flow control by the valve graft.
DETAILED DESCRIPTION OF EMBODIMENTS
[0031] A valve graft 1 according to the present disclosure is shown in FIGS. 1-3 . The valve graft generally comprises a valve frame 10 defining a valve frame open area ( 18 in FIG. 4 ). The open area is spanned by a pair of valve flaps 12 constructed of a biomaterial, discussed below. The valve flaps have positioned therebetween an aperture 14 .
[0032] The valve frame 10 is preferably a closed loop and is commonly constructed of fine-gauge metal (e.g., 0.014 inch diameter), although other materials can be effectively employed. For example, the valve frame can alternatively be made of a synthetic material such as TEFLON (polytetrafluoroethylene). As well, the valve frame can be fabricated of a resorbable or biodegradable composition.
[0033] In one embodiment, the valve frame 10 is a memory wire formed into a desired shape. As illustrated herein, the valve frame is rhomboidal, although other shapes can be utilized to effect a variety of valve shapes and dimensions.
[0034] Such a shape memory wire frame is known in the art as a frame that substantially returns to its original shape after it is deformed and then released, as described in U.S. Pat. No. 4,512,338 (to Balko et al.). The alternative compositions disclosed above also can be of a memory character if desired.
[0035] The valve flaps 12 span the valve frame open area 18 and are suturelessly bonded to the valve frame 10 . An aperture 14 separates the valve flaps and serves as a port through which fluid can traverse the valve graft when in use in a patient's vessel.
[0036] The valve flaps 12 preferably are of a collageneous biomaterial and can be constructed using a variety of collagen-rich biomaterials, e.g., a synthetic collagen matrix or of native tissue-derived, collagen-rich biomaterials such as pericardium, peritoneum, dura mater, fascia and bladder or ureteral acellular matrices.
[0037] An exemplary method for making the valve graft described above is shown in FIGS. 4-8 . In this method, a valve frame 10 is distorted into a flexed state ( FIG. 4 ). In this flexed state, the ratio of the long axis of the frame to its short axis is increased as compared to the base state. In the preferred embodiment wherein the frame is composed of a memory material, it should be apparent that the valve frame will therefore be under tension when flexed.
[0038] The valve frame is then placed on a first major surface 22 of a sheet of biomaterial 20 ( FIGS. 5-6 ). A cross-section through line 6 - 6 of FIG. 5 , corresponding to the short axis of the valve frame, is shown in FIG. 6 . An edge 24 of the biomaterial 20 is folded over the valve frame 10 to contact the edge with the first major surface 22 of the biomaterial ( FIG. 7 ) and form thereby a first bonding locus 30 .
[0039] In this embodiment, the biomaterial 20 is a trimmed portion of porcine intestinal submucosa. The intestinal submucosa graft is harvested and delaminated in accordance with the description in U.S. Pat. Nos. 4,956,178 and 4,902,508 (both to Badylak et al.). An intestinal submucosa segment is thereby obtained that can be effectively used as a biomaterial sheet as described herein.
[0040] Sutureless bonding of the edge 24 of the biomaterial sheet to the first major surface 22 of the sheet is illustrated in FIG. 8 . The sutureless bonding can be achieved using thermal bonding or chemical cross-linking techniques.
[0041] In thermal bonding shown in FIG. 8 , the at least first bonding locus 30 , in which the edge 24 of the biomaterial 20 is apposed to the first major surface 22 thereof, is irradiated with energy 32 sufficiently to heat, denature and fuse together the components of the biomaterial.
[0042] The bonding technique is preferably confined to the selected bonding loci, such that the sutureless bonding effectively “spot-welds” the biomaterial edge to the first major surface of the sheet. Alternatively, the edge can be welded to the first major surface in one or more weld lines.
[0043] In irradiating the at least first bonding locus with energy from an energy source 34 , wherein the energy source is an 800 nm diode laser, propagation of laser energy is preferably directed perpendicular to the biomaterial. The biomaterial, preferably being transparent to the laser light at the chosen light wavelength, absorbs little energy and hence sustains minimal thermal damage. However, the energy-absorbing material at the at least first bonding locus absorbs energy and thereby conducts heat to the adjacent biomaterial.
[0044] Sutureless bonding using thermal energy preferably creates a weld while minimizing transfer of heat to surrounding tissues, thereby reducing collateral thermal damage. The chromophore also can aid in thermal confinement and thereby reduce denaturation of surrounding tissue.
[0045] With sufficient energy irradiation, the biomaterial edge and first major surface at the at least first bonding locus are denatured at the protein level. It is believed that the molecules in the biomaterial intertwine with one another. Upon cooling, the bond site is weld-sealed, wherein the biomaterial edge and first major surface of the biomaterial are welded together.
[0046] As has been mentioned, the valve frame alternatively can be constructed so as to comprise a biological material amenable to laser fusion techniques. With such an embodiment, the collagen-rich biomaterial sheet can be attached to the valve frame by fusion directly thereto, rather than folding the sheet around it and fusing the edge to the first major surface.
[0047] The combination of an energy-absorbing material (i.e., a chromophore, such as indocyanine green (ICG)) and an 800 nm diode laser is the preferred equipment for sutureless bonding in the method herein disclosed. The chromophore can be an endogenous or exogenous substance. The at least first bonding locus at the folded-over edge preferably includes the chromophore, either by treatment of the biomaterial before sutureless bonding or by topical application of a chromophore during sutureless bonding.
[0048] Thermal bonding can be accomplished according to either of two models. In a first model as discussed above, a device is remotely employed to generate heat within the biomaterial. A second thermal bonding model involves contacting a device with the at least first bonding locus for direct generation of heat at the biomaterial contact site. Such devices for contact-heating are known in the art and include a contact thermo-electric transducer.
[0049] In a first alternative sutureless bonding model, the biomaterial edge can be bonded to the first major surface by photo-chemical cross-linking. In a first embodiment of this technique, methylene blue is introduced to the at least first bonding locus and the region is irradiated with white light or other non-collimated light.
[0050] Conventional chemical or photo-crosslinking agents frequently present toxicity concerns if introduced into a patient. For this reason, it is preferable that such agents be avoided or the valve graft well rinsed to remove as much of the agent as possible. Methylene blue is a preferred substance for photochemical cross-linking as described above, because the dye has been shown to be easily rinsed from collagen-rich biomaterials such as SIS.
[0051] The sutureless bonding technique used can vary according to desired locus size, biomaterial, speed, cost, and procedural considerations. In all cases, however, it is apparent that the disclosed method avoids the use of sutures to attach the biomaterial to the prosthesis frame.
[0052] Sutureless bonding as disclosed herein possesses a satisfactory bond strength to permit the valve graft to be implanted into a patient's tubular vessel without increasing the risk of bond failure over that of conventional sutured attachment schemes. As has been mentioned, the presence of sutures at an implantation site increases the probability of post-procedure complications, such as foreign body reaction, thrombogenesis, leakage and reflux of fluid. Use of the sutureless bonding method therefore produces a valve graft more readily received by a patient's body.
[0053] The present method results in thermal fusion of the biomaterial to generate a strong bond. As well, the resulting valve graft provides a high affinity, migratory, and integrative capability for host cell and tissue ingrowth. The bioprosthesis also prevents fluid leakage while retaining a soft, pliable character. Employment of a biomaterial sheath and avoidance of sutures provide a non-carcinogenic valve stent that greatly minimizes calcification and foreign body reactions.
[0054] An aperture 14 is formed in the biomaterial sheet 20 , creating the bidentate valve graft shown herein. The width of the aperture can be varied to control the flexibility of the valve and the maximum flow rate through the valve.
[0055] FIGS. 9-10 are diagrams of one embodiment of a method for implanting a valve graft 1 at an implantation site 40 in a patient's tubular vessel 50 . The valve graft 1 first is folded along one axis (i.e., along reference line A-A in FIG. 1 ), bringing proximate the distal corners of the frame.
[0056] The biomaterial sheet typically is stretched thereby and preferably curves below the short axis and toward the distal corners, taking on a saddle-like shape. Owing to both the composition of the valve frame and the tensile strength of the biomaterial, tension on the biomaterial is not so great as to tear the biomaterial or to pull open the aperture.
[0057] A catheter 60 is preferably employed to introduce the folded valve graft to the implantation site. The valve graft 1 is sufficiently tightly folded to permit the valve graft to be placed within the catheter 60 . This fitment is generally achieved by bringing the distal corners closer and also compressing the frame along the fold axis. The resultant folded valve graft has a high aspect ratio relative to its relaxed orientation (i.e., as shown in FIG. 9 ).
[0058] The catheter 60 is then maneuvered to position the distal tip thereof at the implantation site 40 , such as in a vein 50 . The tightly-folded valve graft is introduced into the vein or other tubular vessel by deployment from the distal tip of the catheter 60 , as shown in FIG. 10 . Such release can be achieved by pushing the valve graft from inside the catheter with a ramrod-type element 62 , such as a guidewire.
[0059] Upon release from the catheter, the valve graft will tend to spring back to its original conformation, limited by the walls of the tubular vessel ( FIGS. 10-11 , with the valve aperture shown open). This expanding tendency is due to the shape memory material of which the valve frame is constructed.
[0060] The valve graft will remain at the implantation site in a folded state, though not so tightly folded as in FIG. 9 . Over time, native tissue overgrowth occurs, further anchoring the valve graft in place.
[0061] A collagen-rich biomaterial sheet can serve as a layer(s) (single or multiple sheets) applied to a supporting structure (e.g., valve frame) to control fluid flow direction through the conduit while preventing leakage out of the conduit. Such valve grafts might be used, for example, in the cardiovascular system (blood vessels), gastrointestinal tract, urinary tract, and trachea
[0062] FIGS. 12-13 show simplified views of the implanted valve graft of FIGS. 10-11 , illustrating unidirectional flow control via valve action. For purposes of explanation, it will be assumed that a valve graft has been implanted in a vein of a patient.
[0063] It should be noted that the flaps 12 or leaflets of the valve graft 1 have a flexible character imparted by the composition of the biomaterial sheet 20 . The flaps 12 therefore can be flexed or bowed by the force of the incident fluid. Such pliant or elastic property is known in the art for “natural tissue” valves, as opposed to mechanical valves.
[0064] In FIG. 12 , anterograde blood flow in the vein 50 is occurring, consistent with normal circulation, i.e., from right to left. Pressure on the upstream surface of the valve graft flaps 12 by the blood (solid arrow) causes the flaps 12 to be bowed toward the walls of the vein 50 . The valve graft aperture 14 is opened thereby, permitting the blood to flow through the valve graft 1 and further downstream (solid arrow) through the vein 50 .
[0065] In retrograde blood flow to the valve (solid arrow, FIG. 13 ), blood fills and is trapped in the “dead-end” regions between the valve graft flaps 12 and the vein wall 50 . This phenomenon, coupled with the continuing-fluid pressure on the flaps 12 caused by physiological blood flow, causes blood to contact and press on the downstream surface of the valve graft flaps, flexing them inward and away from the vessel walls 50 . By bowing the flaps inward, the valve graft aperture 14 is effectively closed and retrograde flow through the valve graft is substantially prevented (dashed arrow).
[0066] A valve graft preferably is constructed in which the aperture is substantially closed when the valve graft is in a resting-state conformation (i.e., its state when implanted in a vessel having no fluid flow). Such construction is dependent on the size, shape, and dimensions of the valve frame, the presence and degree of tension that can be applied to the biomaterial sheet during valve graft fabrication, and the dimensions and orientation of the aperture.
[0067] In another alternative valve graft, the aperture can be designed to incompletely close or to substantially narrow in the face of retrograde flow, depending on the particular configuration and dimensions of the implanted valve graft. If a partial retrograde flow is desired, for example, the aperture dimensions can be chosen to prevent complete closure of the aperture in an in situ implantation.
[0068] Implantation of a valve graft according to the present disclosure provides several benefits over prior art prostheses. Collagen and SIS are known to provide a matrix that encourages native cell repopulation and may ultimately enhance tissue repair and regeneration as well as integration of implanted supporting structure materials.
[0069] One advantage of the disclosed method for making a valve graft is that thermal bonding, and especially laser fusion of the biomaterial edge to the first major surface is a rapid technique that yields water-tight bonds. As well, laser fusion has the capability of attaching multiple biomaterial sheets at numerous locations on their major surfaces, reducing the chance of leakage between the biomaterial sheets.
[0070] Heretofore, laser fusion has not gained widespread acceptance for bonding approximated tissue edges, largely because of weak bond strength. However, laser fusion of collagen-rich biomaterials as described herein resulted in strong tissue bonds. Further, collagen-rich biomaterials have been observed to readily incorporate chromophores such as ICG, further enhancing the efficacy of laser fusion in the present invention.
[0071] Another advantage of the present valve graft over prior art prostheses is that the use of sutures is obviated in the present invention. The risk of a foreign body response is therefore substantially mitigated.
[0072] A further advantage is that a valve graft as disclosed herein and constructed with collageneous biomaterial flaps will retain the excellent bio-active properties of small intestinal submucosa graft with greatly reduced risk of cytotoxicity and foreign body reactions. The sutureless bonding welds provide sufficient mechanical and structural strength to enable the valve graft to be employed in medical procedures and to function acceptably in situ.
[0073] A person skilled in the art will be able to practice the present invention in view of the description present in this document, which is to be taken as a whole. Numerous details have been set forth in order to provide a more thorough understanding of the invention. In other instances, well-known features have not been described in detail in order not to obscure unnecessarily the invention.
[0074] While the invention has been disclosed in its preferred form, the specific embodiments presented herein are not to be considered in a limiting sense. Indeed, it should be readily apparent to those skilled in the art in view of the present description that the invention can be modified in numerous ways. The inventor regards the subject matter of the invention to include all combinations and sub-combinations of the various elements, features, functions and/or properties disclosed herein. | A bioprosthetic valve graft comprises a valve frame and valve flaps, the latter acting to open or close a valve aperture to directionally control fluid flow through the bioprosthesis. The bioprosthetic valve graft comprises method for suturelessly attaching a biomaterial suturelessly bonded to the A method for securing a biomaterial to a valve frame includes positioning a flexible valve frame defining an open area on a first major surface of a biomaterial sheet having a peripheral edge, wherein positioning serves to approximate the valve frame and the peripheral edge of the biomaterial sheet to form an at least first bonding locus: and suturelessly bonding the biomaterial to the valve frame at the at least first bonding locus. The method avoids the disadvantages associated with conventional sutures and substantially reduces medical complications in implantations. | 0 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to games and is particularly directed to balancing games having weighted elements which may be suspended at various locations on extending arms of a balancing device.
II. Description of the Prior Art
Games of skill, chance, and strategy have been known and played over the years with a great variety of playing pieces and structures. However, few of these games combine the skill and strategy inherent in most games with the basic concepts of moments of force and balance as well as chance. Thus, such games when played in the past added little to the knowledge of the participants relative to moments of force and balance. There has been a need to provide a game with a balancing element which would give both enjoyment and instruction in mechanical moments of force. Furthermore, there has been a need to provide a game which can incorporate either a visual or audible alarm to detect an error or foul by the person attempting to maintain balance.
SUMMARY OF THE INVENTION
The present invention provides a game apparatus which involves a variable factor in maintaining balance by suspending weighted elements from a multiple of depending arms balanced atop a support column. The game provides both enjoyment and instruction in moments of force and balance.
The game is suitable for play by children five years of age and older, as well as by adults. The game may be simplified or made more difficult by the positioning of portions of the apparatus as well as by use of the accessories including colored dice and challenge cards.
The invention involves chance and comprises an apparatus for recreation and instruction in moments of force and balance. Various sets of colored and numbered dice may be used as random selection means.
The invention has a support base with a fulcrum such as a pointed portion on the top of the base to balance a balancing element comprising a hub and arms extending therefrom and positioned equidistantly about the hub. Each of the arms has a number of notches formed along the length thereof for the suspension of weights thereon. The weights are placed on the arm so that the hub and extending arms remain relatively balanced above the point on the fulcrum. The player-student learns balance by carefully placing the weights on the arms. The player of the game also learns about moments of force by placing the weights on the proper notches of appropriate arms so that the apparatus does not tip and close an electrical circuit which activates an indicating device such as a light or buzzer. A player obtains points for positioning the weights on the arms without setting off the indicator mechanism.
According to the rules of the game, the player receives a greater number of points for positioning the weights on a more extended portion of the arms. According to various alternative aspects of the game, the points which form electrical contacts or switch means in the apparatus may be moved relative to one another so that the relative skill required in positioning the weight is variable.
Various challenge cards may be used with the apparatus. These cards may, for example, show a starting position for weights on the extending arms and a desired finish position. The player is challenged to accomplish the desired arrangement in the fewest possible moves. Such cards may appear in books or as a newspaper/periodical item. Optionally, the cards may have a preferred sequence of steps for solution on the opposite side thereof.
Each of the extending arms are labelled with indicia such as colors and/or numbers. Dice or spinners may be used to determine which of the arms are to be used during one player's move. Optionally, another die may be used to determine how many of the weights are to be placed on the arms selected by the dice thrown to indicate which arms are to be used.
Preferably, each arm will have three notches cut angularly into the arm so that a weight hanging thereon slides naturally into the notch by gravity.
Also preferably, the notches are located at preselected positions on the arms so that various balance positions are possible. If a weight is placed on corresponding notches of opposing arms, for example the opposed outermost notches, balance is achieved. Furthermore, balance is achieved if two weights are placed at the innermost notch of an arm and one weight is placed at the central notch of the opposite arm. Finally, and preferably, balance is achieved if one weight is suspended on the outermost notch of an arm and three weights are suspended at the innermost notch of the opposing arm. So long as players are aware of the preselected balance positions for opposing arms, strategies may be planned for positioning or repositioning the weights.
The weights and notches formed thereon may be formed in any of various manners so long as the weights are capable of being retained on the arms without falling off. Thus, the weights may be of various shapes. A deck of challenge cards may also be associated with the games so that a player is challenged to place the apparatus in the configuration depicted or otherwise indicated on the card. Many other variations of the game are also possible.
At least three dice are associated with the game. The dice are formed with colored faces. Each die has only two colors associated therewith. The colors on the die represent extending arms attached to the central portion of the game apparatus. Thus, the extending arms are identified by colors equivalent with those on the dice. However, the two arms associated with the colors of one die are never positioned next to each other around the central portion atop the support column. For example, one die has three sides red and three sides purple, another die has three sides blue and three sides green, and the third die has three sides yellow and three sides orange. Thus, the extending arms, in the embodiment with six extending arms, are colored or otherwise identified as orange, yellow, blue, red, green, and purple. However, the arms are colored in such order that two colors associated with a single die are not located adjacent one another.
Preferably, the faces of each die have a number representation such as a numeral thereon. The preferred numerals are 1, 2, and 3. Thus, for example, one of the dice listed above will have the numeral 1 on one red face, the numeral 2 on the second red face, and the numeral 3 on the third red face, and similarly on the three purple faces. Thus each face of each die will not only be colored but will have a single numeral shown thereon. A roll of the above described dice thereby provides a random selection of not only the arms of the apparatus but also the number of weights to be used.
The dice are thrown to determine not only the number of weights which must be suspended on the extending arms of the game apparatus, but also to determine which of the extending arms must be used for balancing the game apparatus.
Play of the game with the weights and extending arms of the device not only requires skill and placement of the weights but also teaches the player moments of force where the weights are hung at various positions on notches along the extending arms. Since a weight position toward the outer portion of an arm exerts a greater moment of force on the central portion, thereby tending to close the circuit to end that player's turn, that position on the extending arm is worth more points for hanging a weight thereon. Thus, a player hangs the weights according to the dice thrown in his turn and, if completed without closing the electrical circuit by improperly balancing or positioning the weights on the extending arms, completes his turn and determines the number of points he has accumulated according to the positions and number of weights.
The game allows for adjustment of the structure of the balancing apparatus so that the contact points for the electrical circuit are more delicately movable and/or are spaced to a greater or lesser distance from each other.
Of course, use of an electrical system in a game also aids in the instruction of students and others about basic circuitry and electricity.
It is, therefore, an object of the present invention to provide a game apparatus which is not only entertaining but gives instructions in moments of force, balance, and electrical circuits.
It is also an object of the present invention to provide a game apparatus having dice which must be properly read by the game player and used to determine proper placement of weights on the balancing apparatus of the game.
It is also an object of the present invention to provide a game which has a signalling device of either the visual or audible type such that the game may be used by handicapped persons.
It is also an object of the present invention to provide an apparatus which is usable by player's of various ages and adjustable so as to meet the skills and knowledge of the players.
It is also an object of the invention to provide a game apparatus wherein challenge cards may also be associated therewith to determine the number of weights and relative position of weights which a player must use in a turn to accumulate points.
It is also an object of the present invention to provide a competitive game of relatively simple construction and easy operation by even the most elementary players.
It is also an object of the present invention to provide a game which may be of a basic design and structure but may otherwise be modified to represent a particular environment such as a space station and spacemen or an underwater station and divers, for example.
It is also an object of the present invention to provide a sturdy game apparatus for use by players of various ages wherein the apparatus may be easily disassembled for transportation and wherein the signalling portion of the apparatus may be removed and located remotely from the balancing portion of the game.
It is also an object of the present invention to provide a game apparatus with a signalling device associated therewith and positioned at any of several locations on the apparatus.
These and other objects of the present invention overcome the deficiencies of the game apparatus of the prior art. A better understanding of the present invention will be had upon a reading of the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section through the balancing apparatus of the present invention showing the stand, support column, balancing point, and central portion supported thereon;
FIG. 2 is a fragmentary sectional view similar to FIG. 1 with weighted elements positioned on one of the extending arms;
FIG. 3 is a fragmented perspective view of the adjustable feature of the support column;
FIG. 4 is a fragmented view of an alternative embodiment of the fulcrum of the support column, shown in section;
FIG. 5 is a schematic representation of the dice associated with the present invention;
FIG. 6 is a sectional view of an alternative embodiment of the present invention having an indicator light in the top of the balancing element; and
FIG. 7 is a top plan view of a challenge card used in conjunction with the balancing apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the device 10 of the present invention includes a support base 12 having a threadably attached surface base section 14 by threads 16. The support base 12 also has an upper section 18, middle section 19, and lower section 17, which attaches to surface base section 14 at its doweled threaded end 20.
Referring now also to FIG. 3, an adjustable collar 22 is slidably force fit onto the upper section 18 of the support base 12. The adjustable collar 22 is formed of an electrically conductive material for a reason to be stated later. As can be readily seen in FIG. 3, the collar 22 is adjustable to various heights so as to expose indicia for various skill levels of the game, such as lines 27. Alternatively, the collar may be threadably received on the upper section 18 of the support base 12. The adjustable collar 22 has a top depending flange 24 which provides a flat surface for electrical contact in a manner to be described hereinafter.
A chamber 26 is formed as part of upper section 18 to receive a fulcrum 28. The fulcrum depicted has a point 30 but may alternatively be formed as a rounded element. The fulcrum 28 may also be seen in FIGS. 2 and 4.
Balanced atop the fulcrum is a balancing element 32 having a hub 34 with a plurality of arms 36 depending therefrom at an angle of about 30° from the horizontal. Optionally, the arms may be formed so as to extend substantially horizontally to facilitate packaging of the parts of the apparatus. In the embodiment shown and described, six arms are preferred. Furthermore, the discussion of the rules and directions of the game will be given relative to the embodiment where the device has six arms depending in a manner described from the hub 34. The balancing element has a conical receptor 38 for mating engagement with the point 30 of fulcrum 28. The conical receptor 38 is lined or formed from an electrically conducting material for reasons explained below.
Referring now also to FIG. 2, weights 40 in the form of washers, each of substantially the same mass, are shown attached to arms 36 at various notches 42 formed along arms 36 at various positions. Each of the arms is formed in a similar manner. In an alternative manner of playing the game, the weights may be formed in a different shape, such as horseshoe shaped as shown in FIG. 3 at 102 or may be made with varying masses to vary the scoring of the game.
Referring again to FIG. 1, means are shown for indicating when the balancing element 32 has been overloaded in one direction. The means comprises an electrical circuit with a power source, electrical indicating means, and switch means. As shown in FIG. 1, the power source is a standard dry cell or cells 44. The electrical indicating means is a light 46 received in a small socket 48. The socket 48 is attached by means of an angle clip 50 which is bolted to horizontal wall section 52 of middle section 19 of the support base 12. A conventional bolt 54 and nut 56 may be used.
An electrical wire 58 is passed through a lower intermediate wall 60 of the support base 12 and then through horizontal wall 52 as well as intermediate wall 62 so as to thread through the wall portion 64 forming chamber 26 and touch the electrically conducting fulcrum 28. Similarly, a second wire 66 passes from contact 76 through the intermediate wall 60 of the support base 12 and is attached to the electrically conducting bracket 50 by means of bolt 54 and nut 56 so as to make contact with socket 48. Another wire 68 in turn leads from socket 48 through intermediate wall 62 of middle section 19 and thence through the side wall portion 70 of upper section 18. In this manner, a contact is formed from wire 68 to the electrically conductive collar 22 with its conductive upper flange 24. Thus, as can be seen from the circuitry shown in FIG. 1, a circuit is completed between the battery and the indicating means or light 46 when the electrically conductive lining of the conical receptor 38 is tipped so that a portion of said conical receptor is in contact with the upper flange 24 of the conductive collar 22, as shown in FIG. 2.
When too many weights 40 (FIG. 2) are placed on the arms 36 associated with one side of the balancing element 32, the balancing element 32 will tip to make contact between conical receptor 38 and upper flange 24 of the electrically conductive collar 22 thereby illuminating light 46. Of course, alternatively, an audible alarm such as a bell or buzzer, shown diagrammatically in FIG. 6 at 104, could be used in addition thereto or in place of the light 46.
As can be seen from the construction of the support base 12 shown in FIG. 1, the base is formed in various sections including upper section 18, middle section 19, and lower section 17 so that they may be fitted together by means of the force fitting caps formed on the ends thereof. For example, tabs 72 may be formed as either a full annular section or as individual tabs and extend to fit snugly within the side walls of section 17. Similarly, the tabs 74 will snugly fit into the side walls of upper section 18. Since the lower section 17 of support base 12 is easily threadably detached from the remainder of support base 12, the entire support base may be disassembled for easy storage or transportation.
In a similar manner, the arms 36 of balancing element 32 may be formed so as to be detachable from the balancing element 32 for ease of storage and transportation. Also, as can be seen, the fulcrum 28 may be formed so that it is removable from chamber 26 so as not to present a hazard.
A contact point 76 is formed so as to contact the negative terminal of dry cell 44. The contact is formed so as to fit into the side walls of lower section 17 and attach to wire 66 in the manner indicated such as by brazing or soldering.
Although a preferred embodiment is shown herein, it should be realized that various alternatives are available, such as, for example, placement of the electrical system outside of the support base 12 as shown diagrammatically at 106 in FIG. 6. Other embodiments are available so long as the electrical contact is available as a switch means between the balancing element 32 and the support base 12. Various formations of this electrical circuit are possible. In the manner shown and described in FIG. 1, the various sections of support base 12 may conveniently be made of different types of plastic whereby the portion containing light 46 is made of translucent plastic and the portion containing the battery, contacts, and wires of the invention are hidden by an opaque plastic. The collar 22 is conveniently made of a movable metal cylinder. A door may be formed in sections 17 and 19 for access to the electrical components.
FIG. 6 shows an alternative embodiment of the present invention. In this embodiment, the light 47 is positioned atop the balancing element 32 so that a circuit is completed from the cell 44 to wire 58 to fulcrum 28 to conical receptor lining 39 and thence to the socket 49 receiving light bulb 47. A wire 51 is required within element 32, as shown, between ring conductor 90 and socket 49.
A still further embodiment is shown in FIG. 4 where the fulcrum 28 is formed with external threads 80 and received in an internally threaded chamber 82 formed as a part of upper section 18.
FIG. 5 is a folded out view of the faces of the dice associated with the game. Dice 84, 85, and 86 are colored dice having the colors indicated in the table below and marked or otherwise depicted thereon.
______________________________________THE DICE______________________________________R = Red P = Purple B = BlueG = Green Y = Yellow O = Orange______________________________________
As can be seen, the three colored dice 84, 85, and 86 have only two of the six colors associated with any one die. Each color appears on three faces of one die. According to the preferred embodiment of the invention, each of the arms 36 has a color associated therewith as an indicium for determining which of the arms 36 are to receive the weights according to the play of the game as described below. Thus, the adjacent arms of the game apparatus have indicia located according to the colored dice 84, 85, and 86 such that no three adjacent arms may be selected by a throw of the three colored dice 84, 85, and 86. Although two adjacent arms may be selected, they are never the two adjacent arms associated with a single die. Therefore, for the construction of the colored dice shown in FIG. 5 and embodiments shown in the other drawings, the arms may be sequentially labelled or otherwise given an indicia in the following order:
Red, Purple, Blue, Green, Yellow,
and Orange, in that order.
Preferably, the dice 84, 85, 86 also have the numerals 1, 2, and 3 indicated thereon as shown so that only these three dice are required to randomly select the arms and number of weights to be suspended. In this manner, only the notches remain to be selected according to the player's strategy.
Optionally associated with the game is a numbered die 87 which is shown schematically and folded out in FIG. 5. The die 87 is of a conventional type having an appropriate number of dots for the number represented by the face. Therefore, although numerals are shown in FIG. 5, a die of conventional construction and marking is also usable with the invention as is any equivalent thereof. The four dice may be thrown together, therefore, to determine which arms are to be selected for placement of the weights 40 and to determine the total number of weights which are to be suspended at any of the various notches 42 on the arms selected. Alternatively, additional numbered dice or various types of numbered dice may also be used to increase or decrease the number of weights which are to be used during a player's turn and suspended on the notches 42 of the arms 36.
In the manner of the construction presented above, a score is always obtainable without depriving a player of any points during a given turn. A more complete description of the rules and directions for the game is given hereinafter.
As an alternative to the dice, challenge cards are usable with the game. Each player draws a challenge card from a deck of cards to determine which configuration he will attempt to construct during his turn. Of course a lone player can use the apparatus with a challenge card. Other variations of selection of the number and placement of weights 40 are also possible. For example, a spinner having more than one indicator arrow and rotatable over a circular color board may be used to determine the number of weights and position at which they are to be suspended. According to this preferred embodiment of the invention, it is not necessary to determine which notch of the indicated arm is required for suspension of the weights 40.
An appropriate weight for each of the suspension weights 40 of the invention would be in the range of one to three ounces. Alternatively, weights of various masses may also be used. It should be realized from a discussion of the above that it is possible to arrange the colored dice and numbered dice so that the arrangement rolled on a given turn is not possible.
GENERAL GAME RULES
According to the preferred playing of the game apparatus of the present invention, a player may move only one weight at a time. That move may consist of either placing a weight onto one of the notches of the indicated arm or movement of the weight to a different notch on that arm. Thus, a player is required to exercise great skill in maintaining the balance of the balancing element 32 while at the same time comprehending the laws of physics related to moments of force. The weights on any arm may be moved in any direction as many times as the player chooses during his turn. However, once a weight has been put onto an arm, it may not be removed therefrom and put onto another arm or taken off of the balancing element completely.
A roll of the dice will determine who the first player is according to the highest total rolled. The first player thereafter rolls the colored dice 84, 85, 86 to determine, according to the indicia indicated, which arms are to be selected and how many weights are to be placed on those arms. The player then places the weights (or moves the weights) one at a time on the colored arms 36 of the apparatus indicated by the colored dice.
The weights must be put on each arm indicated by the colored dice. If the number one is rolled with the red face of a die, the player may choose which notch 42 at which he wishes to position the weight on the "red" arm. Similarly, if the number two is rolled on the orange face of a die, the player chooses the notches of "orange" arm 36 on which he wishes to place weights 40. Of course, the player may rearrange the weights on an arm one at a time to achieve a maximum score since more points are given for positioning a weight at the outermost notch of an arm 36.
For example, three points are given for the outermost of three notches on a given arm, two points for the central notch on a given arm, and one point for the inner notch of the arm. This, of course, is attributable to that law of physics associated with moments of force, that is, weight times distance from the fulcrum determines the moment of force. Since a player who suspends a weight at the outermost notch of a given arm creates a greater moment of force against the opposite side of the balancing element 32, more points are given for such a suspension of a weight 40.
If, at any time during a player's turn, the light becomes illuminated, whether due to poor handling of the weights and balancing element 32 or due to the improper placement of weights according to the moments of force created thereby, the player terminates his turn and receives no points for that turn. At that point, the next player in turn rolls the four dice to determine how many and which arms of the device he will use.
Once a player has touched a weight, he must move that weight, either off from the arm or to a different location on the arm. Also, a player must announce that he has reached the end of his turn to accumulate points.
The game is suitable for play by players age five or older. Any number of players can play, but the time between turns becomes longer with each added player and the complication of the game with the increased number of dice also extends the time of each turn. A score of 75 points or any other value selected and agreed upon by the players determines the winner. Alternatively, the winner may be named at the end of three rounds of play, for example.
Another embodiment of the game apparatus, the balancing element and support base may be formed with the appearance of a space station. Thus, the weighted elements may be formed as spacemen 100 as shown in phantom lines in FIG. 3 or similar elements associated with an outer space environment so as to add an attraction to the game for younger players and others interested in space exploration.
Having described my invention, it will become apparent to those skilled in the art to vary the materials and arrangement of some of the parts of the game including the means for selecting the arms to support weighted elements and the means for selecting the number of weights to be balanced on the arms, without departing from the scope or spirit of the invention as defined by the appended claims. | A game of skill and strategy wherein weighted elements are placed on extending arms attached to a central balancing portion supported above a column. The weights must be carefully distributed so that the arms do not lean too far in one direction so as to close an electrical circuit and actuate a signal device. Conveniently, a battery is located within the central column and a signal device such as a light is mounted atop the central portion to detect closing of the electrical circuit and the player's errant attempt to balance the device. A plurality of dice are rolled to determine on which of the depending arms the weighted elements must be hung. Higher scores are awarded for balancing the weights toward the ends of the extending arms. Challenge cards may also be used to challenge a particular distribution of weights on the game device. | 0 |
This application claims priority, under 35 U.S.C. §119, of U.S. Provisional Application No. 60/471,489, filed May 15, 2003.
BACKGROUND OF THE INVENTION
The present invention relates to scuba diving and more specifically to a submersible tablet for use in writing and drawing.
There are many reasons a scuba diver may need to write or draw underwater. The first is to communicate with other divers. Other uses are to record notes, to aid in gathering reference material, architectural drafting for marine construction and artistic rendering as is done at underwater archeological sites.
Presently most underwater communication is accomplished with hand signals or dive slates. Hand signals can be confusing and are limited in what they can communicate. Dive slates are limited in the amount that they can record by the size of the slate. When the slate is full, new writing can only be added by erasing all previous work. In urgent situations this erasing time can be inconvenient. Some communication is performed electronically but this is expensive and vulnerable to the underwater environment.
The use of multiple pages of waterproof material on a clipboard underwater is awkward because in the marine environment the pages can stick together and are difficult to manipulate especially if the diver is wearing gloves. Multiple page slates also cannot be reused until all previous work has been erased.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a novel submersible drawing and writing tablet in which all writing and drawing is of a permanent nature.
It is also an object of the invention to provide a novel submersible drawing and writing tablet that will provide an unlimited amount of workable media underwater.
It is another object of the invention to provide a novel submersible drawing and writing tablet that can provide workable media quickly and easily in an underwater environment through the use of scrolls rather than pages.
It is also an object of the invention to provide a writing and drawing surface that is phosphorescent to accommodate working in low light conditions.
It is also an object of the invention to provide a novel submersible drawing and writing tablet that is of simple construction, does not involve the use of electronics and is impervious to the demands of the marine environment.
It is another object of the invention to provide a novel submersible drawing and writing tablet that can be economically manufactured and marketed.
It is also an object of the invention to provide a novel submersible drawing and writing tablet that is designed to have a buoyancy underwater that renders it nearly weightless and will shed air and water so as not to encumber the diver as he or she enters or leaves the water.
It is another object of the invention to provide a novel submersible drawing and writing tablet that can be easily disassembled for travel.
These and other objects of the present invention will become apparent to those skilled in the art upon consideration of the following description of the present invention.
According to one aspect of the present invention an underwater writing table includes first and second plastic rollers, first and second rotation knobs fitted at respective ends of the first and second plastic rollers, a face plate positioned between the first and second plastic rollers, and a plastic vellum sheet rolled around the first and second plastic rollers and placed over the face plate, wherein the plastic vellum sheet rolls between the first and second plastic rollers when the first or second rotation knob is rotated by the user.
According to another aspect of the present invention a wrist-mounted underwater writing tablet includes first and second plastic rollers positioned in a direction parallel to the user's arm, first and second rotation knobs fitted at respective ends of the first and second plastic rollers, a cover plate including first and second arm belt slots and first and second vellum slots, and a plastic vellum sheet rolled around the first and second plastic rollers and placed over the cover plate and passing through the first and second vellum slots, wherein the plastic vellum sheet rolls between the first and second plastic rollers when the first or the second rotation knob is rotated by the user.
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself however, both as to organization and method of operation, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the underwater drawing tablet according to the present invention;
FIG. 2 is a detailed diagram showing the drawing frame, the face plate, and the drawer of the first embodiment shown in FIG. 1 ;
FIG. 3 is a detailed diagram showing the drawer latch assembly and handle of the first embodiment shown in FIG. 1 ;
FIG. 4 is a detailed diagram showing the support rails and roller supports of the first embodiment shown in FIG. 1 ;
FIG. 5 is a detailed diagram showing the rollers and knobs of the first embodiment shown in FIG. 1 ;
FIG. 6 is a perspective view of a second embodiment of the underwater drawing tablet according to the present invention;
FIG. 7 is a side view of a second embodiment of the underwater drawing tablet according to the present invention;
FIG. 8 is a top view of the second embodiment shown in FIG. 6 ;
FIG. 9 is a side view of the second embodiment shown in FIG. 6 ;
FIG. 10 is a detailed diagram showing the drawing frame of the second embodiment shown in FIG. 6 ; and
FIG. 11 is a top view of the cover plate of the second embodiment shown in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawing.
First Embodiment
The novel underwater drawing tablet according to the first embodiment of the present invention is a hand held device as shown in FIG. 1 . The diver can draw or write continuously, accessing various writing instruments such as pencils (not shown) stored in a drawer 80 and advancing a plastic writing material easily with one hand while the other stabilizes the tablet through the use of a handle 45 on one side.
The tablet is designed, through the use of buoyant materials such as polystyrene, to have a slightly negative buoyancy at a depth of about fifty feet so that it can be very easy to manipulate underwater and will not sink or ascend rapidly if let go.
Underneath the face plate 1 used as a drawing table is a retractable drawer 80 to hold drawing instruments (not shown) through the use of a hook and loop material on its surface and that of the drawing instrument holders. The drawer 80 can be locked in an extended position or in a retracted position. The drawer 80 does not have sides so that it will not retain air or water during entrances or exits of the water's surface.
On each end of the face plate 1 used as a drawing table are rollers 60 and 65 for holding lengths of plastic vellum 2 (not shown for clarity) used as the drawing support. Through the use of grips 50 on the ends of the rollers 60 and 65 the plastic vellum 2 can be wound from one roller to the other as it is used.
The submersible drawing tablet parts are constructed of various plastic resin materials that are impervious to salt water such as polycarbonate, acrylic Plexiglas and polystyrene. The acrylic Plexiglas is produced in bright florescent colors so that the pallet can be located easily if it is set aside underwater where visibility can be poor.
The submersible drawing tablet is designed so that it can easily be disassembled for travel.
The first embodiment of the submersible writing and drawing tablet will now be described by referring to FIGS. 1-6 . The overall submersible writing and drawing tablet is shown in FIG. 1 .
All writing and illustration is done on rolls of plastic vellum with a writing instrument such as a graphite pencil. The vellum 2 is wound onto the lower vellum roller 60 . The lower roller 60 is made of buoyant polystyrene and has a small diagonal vellum slot 63 on each side of the roller to grasp the vellum as it is being loaded onto the roller. The lower roller 60 is supported by the left and right lower roller supports 35 and 40 . The lower roller 60 extends past the left and right roller supports 35 and 40 and is held in place by the left roller end knob 85 on the left and the rotation knob 50 and the right roller end knob 95 on the right. The vellum 2 is advanced or rewound by turning the rotation knobs 50 . The plastic vellum 2 (not shown for clarity) extends from the lower roller 60 , over the face plate 1 and is attached to the upper vellum roller 65 (not visible in FIG. 1 ) by means of two other diagonal vellum slots 63 shown in FIGS. 1 and 5 . The face plate 1 is constructed of phosphorescent polypropylene or Plexiglas to accommodate working in low light conditions. The face plate 1 can also include a grid (not shown) as a drawing aid. The upper vellum roller 65 is held in place by the right and left roller supports 25 and 30 , the right roller end knob 85 on the left and the rotation knob 50 and the right roller end knob 95 on the right.
The upper roller supports 25 and 30 are connected to the upper support rail 20 by two ⅜″ flat head nylon screws 75 . The lower roller supports 35 and 40 are connected to the lower support rail 15 by two ⅜″ flat head nylon screws 75 shown in FIGS. 1 and 6 . The vellum 2 is held tightly against the face plate 1 by use of the roller tension adjusting knobs 70 that apply pressure when turned clockwise to the upper and lower vellum rollers 60 and 65 . The vellum 2 is also held in place on the face plate 1 by use of the drawing frame 10 . The drawing frame 10 and the face plate 1 are attached to the upper and lower roller supports through separators 100 by four nylon screws 75 located in each corner. Vellum 2 travels between drawing frame 10 and face plate 1 .
The upper and lower support rails 20 and 15 extend beyond the left side of the face plate 1 and drawing frame 10 to provide support for the handle 45 and the drawer latch assembly 55 and 90 , details shown in FIG. 3 . Fitted into the drawer grooves 81 shown in FIG. 4 on the inner sides of the upper and lower support rails 20 and 15 is the drawer 80 .
As shown in FIG. 2 , along the back edge of the drawer 80 is the ¼″ high drawer clasp 83 that is grasped by the drawer release trigger 55 (shown in FIG. 1 ). The drawer release trigger 55 applies pressure to the drawer clasp 83 by use of a common rubber band (not shown) wound through a notch in the trigger 55 and attached to a nylon screw 75 in the upper support rail 20 . This is used to keep the drawer 80 retracted when not in use. The surface of the drawer 80 is covered with hook and loop material so that various writing and drawing instruments (not shown) that utilize the same material can be attached to it.
All the components of the submersible drawing and writing tablet are connected to each other through the use of the nylon screws 75 . The width of the slot in these screws is designed to be used with a large coin such as a fifty-cent piece or a Peso rather than a screwdriver. In this way tools are not needed to assemble or disassemble the submersible tablet and the screws will resist stripping due to the lack of edges of the coins.
Second Embodiment
The second embodiment of the present invention is shown in FIG. 6 and is a smaller version of the submersible writing tablet designed to be worn on the arm of the diver and used primarily for communication between scuba divers and for note taking. This second version also uses plastic vellum 2 stretched between two rollers 60 and 65 running parallel to the diver's arm. Writing on the vellum 2 is accomplished with a graphite pencil 170 held in a holder 140 under the drawing surface between the rollers. This smaller version does not have the utility drawer 80 of the larger version and is not designed to be collapsible. This wrist model also is constructed primarily of polycarbonate, acrylic and polypropylene. The device is worn on the diver's arm through the use of a length of hook and loop material 160 that is attached to the underside of the tablet and can be adjusted to accommodate the circumference of the diver's arm by the use of the hook and loop material.
The Second Embodiment of the submersible writing and drawing tablet will now be described by referring to FIGS. 6-11 . The overall submersible writing and drawing tablet is shown in FIG. 6 .
All writing and illustration is accomplished on rolls of plastic vellum 2 . The vellum 2 is wound onto the lower vellum roller 60 . As in the first embodiment, the roller also has a small diagonal vellum slot 63 on each side of the roller 60 to grasp the vellum as it is being loaded onto the roller 60 .
The lower vellum roller 60 and the upper vellum roller 65 are held in place by the right and left cover plate supports 145 and 150 shown in FIGS. 6 and 8 . Both vellum rollers 60 and 65 fit into openings in the left cover plate support 150 , shown in FIG. 8 , and extend through and beyond openings in the right cover plate support 145 . One of roller knobs 50 is attached by pressure fitting to the right ends of each of the vellum rollers 60 and 65 , shown in FIGS. 6 and 7 .
The second embodiment of the submersible writing tablet is not designed to be dismantled since its small size makes this unnecessary. The vellum is advanced or rewound by turning the rotation knobs 50 . The plastic vellum 2 extends from the lower roller 60 , through the lower vellum slot 155 over the cover plate 125 to the upper vellum roller 65 . The cover plate 125 is constructed of phosphorescent polypropylene or plexiglas to aid with visibility under low light conditions and may also include a grid as a drawing aid (not shown). The vellum 2 then passes through the upper vellum slot 155 to the upper vellum roller 65 and, as in the first embodiment, is attached by means of two diagonal vellum slots 63 .
The vellum 2 is held in place by the drawing frame 10 that is attached to the cover plate 125 by means of four nylon screws 75 that pass through the cover plate 125 and thread into the left and right cover plate supports 145 and 150 . Vellum 2 travels between cover plate 125 and drawing frame 10 . Pencil holder 140 is positioned between the upper and lower vellum rollers 60 and 65 and attached to openings in the left and right cover plate supports 145 and 150 , shown in FIGS. 7 and 8 . Next to the pencil holder 140 is a small opening 135 into which one end of rubberized pencil holding tube 165 is held therein. The other end of pencil holding tube 165 is stretched over one end of the graphite drawing pencil 170 .
The second embodiment of the submersible writing tablet is attachable to the diver's arm by means of a length of hook and loop material forming an arm belt 160 that passes through respective arm belt slots 130 on each side of the cover plate 125 as shown in FIGS. 6 , 7 , and 9 . One end of the arm belt 160 passes through a plastic loop 161 sewn into the opposite end of the belt 160 . The belt 160 is then folded back on itself and attached by means of the hook and loop material.
Thus, it is apparent that in accordance with the present invention an apparatus that fully satisfies the objectives, aims, and advantages is set forth above. While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations, and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations as fall within the scope of the appended claims. | An underwater writing and drawing tablet that stretches a length of waterproof (plastic) vellum between two rollers over a flat surface thereby enabling the user to easily draw or write on said vellum and permanently save the drawing and writing. | 1 |
BACKGROUND OF THE INVENTION
The present invention concerns a driving and control mechanism for a device for clamping, holding and presenting weft threads in gripper weaving looms. The mechanism is designed to move thread presentation elements, such as thread clamps or thread eyelets to various positions in relationship to the shed.
According to a preferred embodiment, the invention concerns a driving and control mechanism, that is particularly suitable for driving and controlling thread clamps. The thread clamps are able to take three positions as described in detail in U.S. patent application Ser. No. 033,739 of the applicant. This application describes a method for weaving without waste on the weft insertion side whereby, in a first position, such a thread clamp is in motionless condition; in a second position the thread clamp is presented in such a way that the clamped thread is brought into the path of a gripper and, whereby, in a third position, the clamp is positioned near the cloth edge in such a way that the weft thread introduced into the shed by means of the beating movement of the reed is pushed back into the clamp.
The present invention concerns a driving and control mechanism for such clamps, whereby during two successive cycles of such a clamp, it may not be brought back to the first position, but may directly be brought from the aforesaid third position to the aforesaid second position.
Belgian patent No. 897,288 describes presentation needles which are driven by means of levers mounted on cam wheels and which are connected on one side to the presentation needles while their other end can be held by means of connectable hook elements. These hook elements can only be engaged with the levers when the presentation needles are in their motionless position. This design has, however, the disadvantage that it is not applicable for regulation whereby, as already mentioned, the thread presentation elements arrive only for a short while at their motionless position or not at all in the case of overlapping cycles.
SUMMARY OF THE INVENTION
The present invention relates to a driving and control mechanism for thread presentation elements in gripper weaving looms, that does not have the aforesaid disadvantage and one that makes possible a large range of movement possibilities for the thread presentation elements.
To this end, the present invention comprises a driving and control mechanism for thread presentation elements in gripper weaving looms, whereby at least one thread presentation element can be moved into different positions, whereby the selection does not take place in one of the outer positions. This mechanism is characterized by the fact that it comprises a combination of: for each thread presentation element, at least two levers cooperating with one lever arm in a common manner with coupling means, whereby the coupling means achieve the connection between the levers and the thread presentation element; cam transmissions for moving the levers; locking means able to act on the levers located opposite to the lever arms cooperating with the coupling means; and control means for controlling the locking means.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the characteristics of the invention are better understood, a few preferred embodiments will be described hereafter without any limitative character and with reference to the figures in which:
FIG. 1 is a partial, perspective illustration of a driving and control mechanism for a thread presentation element in accordance with the invention;
FIG. 2 is a graph indicating the movement of the thread presentation element of the embodiment in accordance with FIG. 1;
FIG. 3 is a graphical analysis of the curve in FIG. 2, whereby each of the curves illustrated corresponds to separate movements obtained by means of the aforesaid different levers;
FIG. 4 is a top view of a driving and control mechanism according to the invention whereby four thread presentation elements are driven;
FIG. 5 is a cross-section taken along line V--V in FIG. 4;
FIG. 6 is an enlarged graph of the part of FIG. 2 indicated by F6, whereby the overlapping of two weaving cycles is illustrated;
FIG. 7 is a graph illustrating the cam pattern of a cam transmission that is part of the aforesaid control means, according to a specific embodiment, in order to control the locking means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an embodiment of the invention, whereby a thread presentation element 1 as described in U.S. patent application Ser. No. 033,739 mainly composed of a thread clamp 2, must be controlled in such a way that it can take three positions, respectively A, B and C, near the cloth edge 3, and more specially on the weft insertion side of the shed 4.
The driving and control mechanism in accordance with the invention comprises two levers 5 and 6; coupling means 7 which connects the levers 5 and 6 and the thread presentation element 1; cam transmissions 8 and 9 for moving the levers 5 and 6; locking means 10; and control means 11 for controlling the locking means 10.
The levers 5 and 6 are mounted near each other in the embodiment of FIG. 1 and can move along parallel planes in such a way that they can cooperates with one of their lever arms, respectively 12 and 13 and in a common manner with the coupling means 7. To this end the lever arms 12 and 13 are pivotally connected at their ends, respectively 14 and 15, to each other as well as with the coupling means 7, for instance by means of a shaft 16. The other lever arms, respectively 17 and 18, cooperate with their ends 19 and 20, with the locking means 10.
According to the embodiment of FIG. 1, the coupling means 7 comprises a connecting rod 21, a crankshaft 22 that is fastened on the shaft 23 and an arm 24 fastened on this shaft.
The connecting rod 21 is pivotally connected at one end 25 by means of shaft to the levers 5 and 6. At its other end 26, the connecting rod 21 is coupled to the crankshaft 22. The shaft 23, whereon the crankshaft 22 is fastened, is rotatably supported in the frame 27 of the apparatus.
The thread presentation element 1 is supported by the end of the aforesaid rotatable arm 24.
The cam transmissions 8 and 9 each comprise a cam wheel, respectively 29 and 30, mounted on a common driving shaft 28, whereby these cam wheels bear against the levers 5 and 6 in their centers, respectively cam followers 31 and 32.
The locking means 10 illustrated in FIG. 1 comprises rotatable hook elements 33 and 34 that can engage the ends 19 and 20 of the levers 5 and 6, whereby the upwards movement of these ends 19 and 20 can be prohibited. The control means 11 used to this end are, for instance, of the electro-magnetic type and c o mprise, as illustrated in FIG. 1, rods 35 and 36 that can be moved by means of electro-magnets 37 and 38, and displace the rotatable hook elements 33 and 34.
FIG. 1 illustrates also elastic means designed to bring always the clamp 2 to an initial motionless condition, which is position A in the present case. These means are composed, for instance, of a compression spring 39 which urges the crankshaft 22 downwards. In order to limit the movement, a stop 40 is provided. The levers 5 and 6 can also be equipped with elastic means 41 in order to ensure contact between the cam followers 31 and 32 of levers 5 and 6, the cam wheels 29 and 30 at high speeds of the driving shaft 28. These latter elastic means 41 can also be used in order to move the whole assembly to the initial motionless position instead of obtaining this result by means of a spring 39.
The functioning of the driving and control mechanism in accordance with the invention is described hereafter. When the locking means 10 disengaged from ends 19 and 20 of levers 5 and 6 as illustrated with dotted lines in FIG. 1, the thread presentation element 1 is kept in the initial A position by means of a compression spring 39 acting on the coupling means 7. Consequently the levers 5 and 6 are moved up and down by contact of their followers 31 and 32 with cam wheels 29 and 30 whereby the only result of this movement is an up and down displacement of the ends 19 and 20 of the lever arms 17 and 18, while the coupling means 7 are not moved.
When the locking means 10 are brought into service by means of the control elements 11, the hook element 33 is engaged according to the illustrated embodiment with the end 19 of the lever arm 17. As soon as the lever 5 is pushed upwards by contact between its follower 31 and cam wheel 29, the levers 5 and 6 are also pushed upwards at their coupled ends 14 and 15, whereby the coupling means 7 are moved against the force of the spring 39 and of the elastic means 41, in such a way that the thread clamp 2 is moved to another position. In this case, the movement of the thread clamp 2 is determined by the shape of the cam wheel 29.
After clamp 2 reaches the B position, the hook element 34 is also brought into its operative position near the end 20 of the lever 6. If the cam transmissions 8 and 9 are rotated further, the lever 5 is moved downwards by means of its contact with follower 31 and the cam wheel 29. As the ends 14 and 15 of the levers 5 and 6 are coupled with each other, the lever 6 rotates about its follower 32 over the cam wheel 30 until the end 20 comes into contact with the hook element 34. At this moment, the cam wheel 30 determines the movement of the lever 6 and a while in the C position.
During these periods the hook element 33 will be retracted.
When the cam wheel 30 is rotated further, the follower 32 of the lever 6 is also moved downwards, whereby the clamp 2 returns to its initial motionless position A. At that moment, hook element 34 is retracted and the end 20 of the lever 6 is free again.
The downwards movement of the ends 14 and 15 of the levers 5 and 6 and, consequently, also the downwards movement of the coupling means 7 take place by means of the spring 39 and of the elastic means 41.
The movement of the thread clamp 2 is caused by the levers 5 or 6 which undergo the largest upwards displacement caused by the cam transmissions 8 or 9.
FIG. 2 illustrates a complete revolution of the driving shaft 28 and the corresponding movement of the thread clamp 2 by means of the mechanism illustrated in FIG. 1. The locking means 10 must obviously be brought into service in this case.
The thread clamp 2 is brought from the initial motionless A position to the B position following an initial angular rotation of shaft 28 and is moved afterwards to an intermediate C position during a large part of the revolution cycle. The curve of FIG. 2 also illustrates the movement of the connecting rod 21.
The movement obtained from cam wheel 29 by locking the lever 5 is illustrated in FIG. 3 by curve 42. On the other hand, the movement from cam wheel 30 by locking the lever 6 is illustrated on curve 43. Quite obviously, the curve of FIG. 2 is a combination of both curves 42 and 43, whereby it assumes at each moment, the profile of curves 42 or 43 having the largest instantaneous amplitude.
FIGS. 2 and 3 illustrate also very clearly the advantage of the use of the two levers 5 and 6. If, by means of one lever, a movement must be applied to a thread clamp 2, as illustrated by the curve of FIG. 2, the cam wheel must be designed in such a way that the cam curve has the same shape as the curve of FIG. 2. The lever end cooperating with the locking means comes only for a short while in its lowest A position, in such a case whereby this position is determined by the lowest points 44 of the curve of FIG. 2.
As this lever is able to cooperate with the locking means only at these moments, practically no time is made available for switching on or off the locking means. Practically no movement of a thread clamp, as illustrated by the curve of FIG. 2 can be achieved by means of a device comprising only one lever and one cam wheel.
FIG. 3 clearly illustrates the fact that the previous problem is no longer existing if two or more levers are used, for instance 5 and 6 which are actuated by separate cam transmissions 8 and 9. For an adequate shape of the cam wheels 29 and 30, it is possible to foresee two periods T1 and T2, during which the hook elements 33 and 34 are able to engage the levers 5 and 6, whereby these periods T1 and T2 now correspond to more or less half of the time required for a revolution of the driving shaft 28.
FIGS. 4 and 5 illustrate an embodiment of a driving and control mechanism for four thread presentation elements. The mechanism mainly comprises the combination of four mechanisms as illustrated in FIG. 1, whereby these four elements are mounted on a common driving shaft 28.
The corresponding parts are thus indicated by the same reference numbers.
As shown in FIGS. 4 and 5, the whole assembly is mounted in a casing 45, whereby the arms 24 as well as a part of the shaft 28 are located outside casing 45 and whereby this part of the shaft 29 is equipped with a toothed belt pulley 46 that can be coupled to the main transmission (not shown) of the weaving loom.
Another specific characteristic of the embodiment according to FIGS. 4 and 5 is related to the fact that the cam transmission 8 of the four levers 5 is built in a common manner. To this end, the cam transmission is composed of two cam wheels 29; a shaft 49 supporting cam followers 31; and of means 50 for fastening shaft 49 at its ends to the casing 45 for adequate movement. The cam wheels 29 are mounted respectively along both sides of the lever system while the shaft 49 supports four levers 5.
The means 50 providing the movable fastening of the shaft 49 comprise crankshafts 51 and 52 that are coupled each at one end to the shaft 49 and that are pivotally supported at their other end in the casing 45 whereby the pivot center is on the same line as the points of contact between the ends 19 and the hook element 33.
Two compression springs 53 and 54 urge cam followers 31A supported on shaft 49 into contact with the cam wheels 29. The springs 55 urge cam followers 32 on levers 6 into contact with corresponding cam wheels 30.
The control means 11 comprise a cam transmission 56, having for each hook element 33 and 34 a cam wheel 57 and 58, respectively, as well as electro-magnets 59 and 60 which cooperate in known fashion with the lever arms 61 and 62 fastened to the hook elements 33 and 34.
The cam wheels 57 and 58 are mounted on a common shaft 63 which is coupled to the driving shaft 28 by means of a gear transmission 64. The cam wheels 57 and 58 push the lever arms 61 and 62 against the electro-magnets 59 and 60 once for each revolution of shaft 63.
To obtain the movements illustrated by the curves of FIGS. 2 and 3, the lever arms 61 and 62 must be actuated respectively during the periods T1 and T2. The cam curves 65 and 66 for the cam wheels 57 and 58 are illustrated in FIG. 7. Retracting means 67 are attached to the lever arms 61 and 62 to return them to their retracted positions.
The functioning of the driving and control mechanism for thread presentation elements according to FIG. 5 is essentially corresponding to the working of the embodiment according to FIG. 1.
The thread clamp 2 is put into operation in the following manner. When a thread clamp 2 is selected, the corresponding electro-magnet 59 is energized. By means of the cam wheels 57, all lever arms 61 are pushed against their respective electro-magnets, following the curve 65. Only the lever arm 61 which is cooperating with the switched-on electro-magnet 59 will be kept at its highest position during the folloiwng cycle, while the other lever arms 61 will be kept in contact with their cam wheels 57 by means of the retracting means 67.
The lever arm 61 held by the electro-magnet 59 engages the hook element 33 with the end 19 of the corresponding lever 5. The functioning is then similar to that of the embodiment described in accordance with FIG. 1 and the clamp is moved to the B position.
The movement of the clamp 2 from the second B position to the waiting condition of the C position will occur as follows. The corresponding magnet 60 is energized. By means of the cam wheels 58 all lever arms 62 are pushed against the electro-magnet 60 as indicated by curve 66 in FIG. 7. Only the lever arm 62 that is cooperating with the switched-on electro-magnet 60, and thus the lever arm of the clamp 2 just selected and moving along curve 42, will be kept in the highest position during the continuation of the cycle, while the other lever arms 62 will be kept in contact with the cam wheels 58 by means of the retracting means 67. The downwards forces applied afterwards by the cam transmission 8 to the levers 5 and the upwards forces applied by the cam transmission 9 to the levers 6 keep the selected clamp 2 in the C position, while, by the cooperation of the corresponding lever 6 with the cam transmission 9 and the hook element 34, the clamp 2 is held in the C position during a part of the cycle. Meanwhile, the hook element 33 that was engaged with lever 5 is retracted to free end 19 of the lever. Subsequently, a new selection can be carried out for the lever 61 and the hook element 33.
Quite obviously various alternative solutions for the driving and control mechanism in accordance with the invention are possible. For instance locking means 10 other than hook elements 33 and 34 may be resorted to.
The coupling means 7 may comprise for instance, a rod that is directly connected to the thread clamp 2, whereby the thread clamp 2 can be moved vertically up and down.
Moreover, various movements can be applied to the thread presentation element 1 by means of a driving and control mechanism in accordance with the invention, and it is obvious that the movements, as well as the shapes of the cam wheels 29 and 30, as illustrated in FIGS. 2 and 3 are given only by way of examples.
According to an alternative solution that is not illustrated in the figures, the two levers 5 and 6 may also be mounted in a common plane, whereby the cam transmissions 8 and 9 are mounted on the left and right hand sides of and near the coupling means 7.
According to still another alternative solution, the cam wheels 8 and 9 as well as the levers 5 and 6 can be mounted one above the other, whereby, for instance, in the embodiment according to FIG. 1 the end 14 of the lever 5 cooperates with the end 25 of the connecting rod 21, while the end 13 of the lever 6 cooperates with the lowest end 26 of the connecting part 21.
The use of two or more levers has the advantage that overlappingmovements of two thread presentation elements 1 can occur as illustrated on the diagram of FIG. 6. The movement according to curve 68 (which is an alternative to the curve 43) of FIG. 6 for the thread presentation element 1 which was the last in working must not necessarily be finished at the beginning of the movement, according to curve 69 (which is an alternative to curve 43) for the next thread presentation element to be activated.
The present invention is by no means limited to the embodiments described hereabove by way of examples and illustrated in the figures, but such a driving and control mechanism for thread presentation elements of gripper weaving looms can be carried out in many shapes and sizes without departing from the scope of the invention. | A driving and control mechanism for clamping, presenting and holding weft threads on gripper weaving looms is disclosed, whereby at least one thread presentation element (1) can be moved to various positions. The mechanism is composed of at least two levers (5, 6) which are attached in a common manner with a coupling connecting the levers (5, 6) to a thread presentation element (1), a cam transmission (8, 9) for moving the levers (5, 6) locking device (10) which can actuate the lever arms (17, 18) located opposite to the lever arms (12, 13) attached to the coupling (7); and a control system (11) for actuating the locking device (10). | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of international application PCT/EP2004/003454, filed Apr. 1, 2004, and which designates the U.S. The disclosure of the referenced application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a process for the production of BCF yarns as well as a apparatus for the production of BCF yarns.
[0003] The production of so-called BCF (bulked continuous filament) yarns is accomplished in a one-step spinning process, and the resulting melt-spun and bulked BCF yarns are used mainly for carpet yarns. In the spinning process, a plurality of strand-like filaments are extruded, cooled, and consolidated into a bundle to form a yarn, which is then drawn, bulked, and wound into a package. The filament strands consolidated to form the yarn are extruded in the form of a bundle by means of a spinneret which comprises on its underside one nozzle hole for each of the filaments. Thus, several filament bundles are extruded by several spinnerets. In order to produce several yarns in parallel side by side in spinning processes of this type, basically two system concepts are known.
[0004] EP 0 363 317 A2 and corresponding U.S. Pat. No. 5,059,104 disclose a process and a apparatus in which each of the filament bundles forming a yarn is extruded by one spinneret. The spinnerets are disposed side by side to form an annular arrangement so that the individual filament bundles are fed, in an annular arrangement, to a cooling zone. The cooling is done by a cool air flow produced from the inside outward. After the cooling the filament bundles are consolidated to form the yarns, and subsequently drawn, textured, and wound into packages.
[0005] Different from this, a second system concept for the production of BCF yarns also follows from EP 0 363 317 A2. In this known process and the known apparatus the filament strands forming a yarn are extruded by means of a spinneret. For the production of several yarns the spinnerets are disposed side by side in a row arrangement so that for the production of several yarns the spinning apparatus requires a correspondingly large space.
[0006] The processes and apparatus known in the state of the art have, in principle, the disadvantage that the filament strands are extruded in the form of a bundle so that to form yarns with relatively large total titer a high filament density is reached during the extrusion, which does not ensure a uniform cooling of all the filament strands. The bundle-like arrangement of the filaments during the extrusion has in addition the disadvantage that a cool air flow directed from outside onto the bundle of filament strands leads to the filament strands experiencing a lower cooling in the interior of the bundle than the filament strands which are fed at the outer edge of the bundle. In the production of BCF yarns the requirement of uniformity is particularly high since further processing is not provided. Particular importance falls to the cooling because the physical characteristics of the filaments are directly affected thereby.
[0007] It is an object of the invention to provide a process and an apparatus for the production of BCF yarns in which the filaments consolidated to form yarns have a high uniformity in quality.
[0008] It is an additional object of the invention to provide a process and an apparatus of the type mentioned initially with which BCF yarns can be produced with a high melt throughput and high filament density.
[0009] It is also an object of the invention to provide a process and an apparatus for the production of BCF yarns of the generic type in which a flexible division of the filament strands to form several yarns is possible.
SUMMARY OF THE INVENTION
[0010] The above and other objects and advantages of the present invention are achieved by the provision of a process and apparatus wherein a downwardly advancing annular filament sheet is extruded, and the advancing filament sheet is cooled by directing a cool air flow from the inside of the annular sheet outward through the sheet. Also, the annular filament sheet is divided into segments which are each gathered to form a multifilament yarn. Thereafter, each of the yarns is drawn and bulked, and then wound into a package.
[0011] The invention turns away completely from the known system concepts in which the division of the filaments to form the yarns is done during the extrusion. The invention is based on the fact that a division of the filament strands to form the yarns is only necessary after the extrusion. In particular, the invention combines into a single process the extrusion and the cooling of the plurality of the filaments which form several yarns.
[0012] The particular advantage of the invention is given by the fact that each of the filaments fed within the filament sheet can be cooled uniformly. Here the conditions for extrusion and cooling of the filaments are unaffected by the subsequently formed total titer of the individual yarns. Thus, for example, the number of filaments per yarn can be increased by a larger segment of the annular filament sheet being consolidated.
[0013] The invention was also not obvious due to the fact that in the state of the art spinning apparatus for the production of staple fibers are known, e.g. from EP 1 247 883 A2 and corresponding U.S. Publ. No. 2002145219, in which a filament sheet arranged as a ring is extruded and consolidated to form a spinning cable. Processes and apparatus of this type are designed to cool, extrude, cool, and consolidate a plurality of filaments. In so doing, preferably several annular filament sheets are connected to form a total tow. However, processes and apparatus of this type are completely unsuitable to produce several separately fed and treated yarns.
[0014] For the extrusion of the annular filament sheet forming the BCF yarns the so-called ring spinneret is particularly advantageously suited. Ring spinnerets of this type have on their underside a plurality of nozzle holes which are formed in an annular arrangement. The nozzle holes are disposed, preferably symmetrically, in several rows of holes formed to be concentric to one another. With this, in particular, relatively large filter surfaces can be realized which make possible a high throughput per ring spinneret, specifically more than 150 kg/h.
[0015] In order to be able to carry out, in a simple manner, the division of the filament sheet after the cooling, the embodiment of the invention is particularly advantageous in which the annular filament sheet is extruded by several segments of the rings of holes, said segments forming the annular arrangement of nozzle holes of the ring spinneret, and in which the portion of the filament sheet extruded by one of the segments of the rings of holes is consolidated to form one of the yarns. With that, it can advantageously be ensured that each of the yarns has the same number of filaments.
[0016] To produce monocolor BCF yarns the ring spinneret's segments of the rings of holes are provided with a polymer melt by a common diffuser chamber. Along with this, additional diffuser or filter elements can be disposed before a nozzle plate containing the nozzle hole.
[0017] In another embodiment of the invention, several separate diffuser chambers are formed within the ring spinneret which are each connected to a segment of a ring of holes, or a group of segments of the rings of holes, and through which several polymer melts are diffused to their assigned segments of the rings of holes. This is particularly suitable for producing multicolor BCF yarns. For this, several polymer melts are fed for extrusion of the filament sheet, via the diffuser chamber, to their assigned segment of a ring of holes of the ring spinneret and extruded.
[0018] For obtaining a uniform cooling of all the filaments fed in the filament sheet along the entire circumferential surface of the annular filament sheet, the cool air produced by a blowing plug has shown itself to be particularly effective. Through the gas-permeable jacket of the blowing plug a uniform cool air flow is produced in a plurality of radial directions. Here, zones of different gas permeability can be formed on the jacket of the blowing plug in order to produce different cooling zones for cooling or certain blowing profiles of the cool air.
[0019] An additional, a particularly advantageous embodiment of the invention is provided by the filament sheet receiving a preparation before the division to form the yarns. Through the annular arrangement of the filament sheet, a uniform application to all the filaments can be produced by external or internal preparation rings.
[0020] To divide the filament sheet fed as a ring, the dividing apparatus can be formed below the cooling zone by several yarn feeders which are disposed at intervals on a diffuser ring corresponding to the segment-like division of the filament sheet. Here the diffuser ring can be disposed within the filament sheet or outside of the filament sheet.
[0021] A particularly advantageous embodiment of the invention is given by the division of the yarn feeders of the dividing apparatus in a plane. With this, the extension of the yarns can be followed immediately by drawing, bulking, and winding. With the process according to the invention and the apparatus according to the invention, BCF yarns of the most varied type as well as of different yarn material, such as, for example, polyamide, polypropylene, or polyester, can be produced.
[0022] The process according to the invention is described in the following with reference to several exemplary embodiments of the apparatus according to the invention and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In the drawings:
[0024] FIG. 1 schematically illustrates the structure of a first embodiment of the apparatus according to the invention,
[0025] FIG. 2 . 1 schematically illustrates the underside of an embodiment of a ring spinneret which could be used with the apparatus of FIG. 1 ,
[0026] FIG. 2 . 2 is a fragmentary cross sectional view of the ring spinneret of FIG. 2 . 1 ,
[0027] FIG. 3 schematically illustrates an additional embodiment of the apparatus according to the invention,
[0028] FIG. 4 schematically illustrates the underside of the ring spinneret from the embodiment according to FIG. 3 ,
[0029] FIG. 5 schematically illustrates an additional embodiment of an apparatus according to the invention, and
[0030] FIG. 6 schematically illustrates the structure of an embodiment of a dividing apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] In FIG. 1 the structure of an embodiment of the apparatus according to the invention and for carrying out the process according to the invention is shown in schematic form. The embodiment is composed of a spinning apparatus 1 , a cooling apparatus 2 , a dividing apparatus 13 , a stretching or drawing apparatus 3 , a bulking apparatus 4 , and a winding apparatus 5 which are arranged to form a yarn path.
[0032] The spinning apparatus 1 comprises a nozzle holder 16 which on its underside comprises a ring spinneret 17 acting as nozzle means. The ring spinneret 17 is connected, via a melt diffuser 18 , to a spinning pump 15 . The spinning pump 15 receives, via a melt intake 14 , a melted polymer material. The heating and melting of the polymer material is done preferably by an extruder which is not represented here. The spinning pump 15 can be formed as a single pump or as multiple pumps.
[0033] The ring spinneret 17 comprises on its underside an annular nozzle plate 20 which contains a plurality of nozzle holes. Within the nozzle plate 20 the nozzle holes are preferably formed in several consecutively disposed concentric rows of holes.
[0034] Below the spinning apparatus 1 the cooling apparatus 2 is disposed, which comprises a blowing means 19 held in the center relative to the ring spinneret 17 , e.g. a blowing cylinder with an air-permeable wall. The blowing means 19 is connected, via an air intake not represented here, to a cooling air source so that on the circumferential face of the cylindrical blowing means 19 a cool air flow exiting in the radial direction is produced.
[0035] Between the cooling apparatus 2 and the winding apparatus 5 a dividing apparatus 13 for dividing a filament sheet into several yarns, a drawing apparatus 3 for drawing or stretching the yarns, and a bulking apparatus 4 for bulking the yarns are disposed consecutively in the yarn path. The means used within the dividing apparatus 13 , the drawing apparatus 3 , and the bulking apparatus 4 to feed and/or treat the yarns is not shown in more detail at this point. In principle, any of the known means can be used which can execute the functions assigned to the apparatus.
[0036] Also represented only in schematic form is the winding apparatus 5 , which includes a projecting spindle 11 which is held and driven by a spindle bearing 12 . On the spindle 11 , three yarn packages 10 . 1 , 10 . 2 , and 10 . 3 are wound side by side. Winding machines of this type for winding BCF yarns are preferably formed by machines which comprise two spool spindles which are held on a movable bearing in such a manner that a continuous winding of the yarns is possible by changing the relative positions of the spool spindles. Other conventional components of the winding apparatus, such as a package changing apparatus and a pressure roll, are not represented here. A winding machine of this type is known, for example, from WO 96/01222 so that at this point reference is made to this publication.
[0037] In the embodiment of FIG. 1 , for the production of a total of three BCF yarns, first a polymer melt, e.g. of polyamide or polypropylene, in the spinning apparatus 1 is fed through the spinning pump 15 and to the ring spinneret 17 . In so doing, the polymer melt is held under a melt pressure so that strand-like filaments 6 are extruded from the nozzle holes of the ring spinneret 17 . The plurality of filaments 6 exiting from the nozzle holes of the ring spinneret 17 form an annular filament sheet 7 . The filament sheet 7 is drawn off from the spinning apparatus 1 by the drawing apparatus 3 or by an additional draw-off element disposed in between.
[0038] Below the spinning apparatus 1 a cool air flow is produced by the blowing means 19 of the cooling apparatus 2 , said cool air flow penetrating the annular veil of the filament sheet 7 uniformly. Thereby a cooling occurs and thus a solidification of the individual filaments 6 of the annular filament sheet 7 . After the filaments 6 are solidified, the filament sheet 7 arrives at the dividing apparatus 13 . Here a segment-like division of the annular filament sheet 7 into several yarns takes place. In the embodiment of FIG. 1 , the filament sheet 7 is divided into three yarns 8 . 1 , 8 . 2 , and 8 . 3 . Each of the yarns 8 . 1 , 8 . 2 , and 8 . 3 is subsequently drawn by the drawing apparatus 3 . For this, roller systems are preferably used which stretch the yarns in parallel and in common. However, it is also possible to draw each of the yarns 8 . 1 to 8 . 3 separately.
[0039] After the drawing, the yarns 8 . 1 to 8 . 3 are bulked in the bulking apparatus 4 . In order to obtain typical bulking for the BCF yarns, the bulking apparatus preferably comprises several texturing nozzles which compress each of the yarns 8 . 1 to 8 . 3 by a hot air flow to form a yarn plug which is fed after actuation of the winding apparatus 5 . In the winding apparatus 5 each of the bulked yarns is wound to form a package 10 . 1 , 10 . 2 , and 10 . 3 .
[0040] The BCF yarns produced with the process according to the invention are distinguished by a particularly high uniformity of the characteristics of the individual filaments. The uniform characteristics of the filaments cause in addition a uniform bulking so that, along with the physical characteristics, the visual characteristics of these BCF yarns also have a particularly advantageous appearance.
[0041] In FIG. 2 . 1 an embodiment of the ring spinneret 17 is shown, as it would be possible to use, for example, in the embodiment according to FIG. 1 . FIG. 2 . 1 is a view of the underside of a ring spinneret and FIG. 2 . 2 a partial cross section of the ring spinneret. In so far as no express reference to one of the figures is made, the following description applies to both figures.
[0042] The ring spinneret 17 is held by a nozzle holder 16 . The nozzle holder 16 can, for example, be held on a spinning beam which comprises several nozzle holders side by side. The ring spinneret 17 comprises on the underside a nozzle plate 20 which contains a plurality of nozzle holes 24 . The nozzle plate 20 is formed as a ring. The plurality of nozzle holes 24 are divided in the nozzle plate 20 into three groups, each of which forms a segment 25 . 1 , 25 . 2 , and 25 . 3 of the rings of holes. The segments 25 . 1 , 25 . 2 , and 25 . 3 of the rings of holes have identical forms. Between the segments 25 . 1 , 25 . 2 , and 25 . 3 of the rings of holes partial sections are formed in the nozzle plate 20 which contain no nozzle holes. Thus, small gaps are formed during the extrusion of the annular filament sheet which are used to divide the annular filament sheet. With this, a precise division of the entire filament sheet is made possible in a simple manner.
[0043] As represented in FIG. 2 . 2 , in the ring spinneret 17 a diffuser chamber 21 is disposed above the nozzle plate 20 , the diffuser chamber also being formed as a ring. Within the diffuser chamber 21 a perforated plate 22 and a filter insert 23 are disposed above the nozzle plate 20 so that the polymer melt passing through the nozzle holes 24 of the nozzle plate 20 has been filtered previously through the filter insert 23 . The diffuser chamber 21 extends within the ring spinneret 17 in the form of a ring above the nozzle plate 20 .
[0044] The diffuser chamber 21 is, as represented in FIG. 1 , connected, via a melt diffuser 18 , to the spinning pump 15 . Here the melt diffuser 18 could be formed by a line system which contains several melt lines emptying into the diffuser chamber 21 . Via the diffuser chamber 21 the polymer melt is diffused uniformly in the ring spinneret 17 and extruded by the segments of the rings of holes of the nozzle plate to form the annular filament sheet. Ring spinnerets of this type are thus advantageous for producing BCF yarns from a polymer melt which is not dyed, or dyed with a certain dye.
[0045] In FIG. 3 an additional embodiment of the apparatus according to the invention for carrying out the process according to the invention is represented in a basic schematic form. The basic structure of the embodiment according to FIG. 3 is essentially identical to the foregoing embodiment of the apparatus according to the invention so that reference is made to the foregoing description and at this point only the differences will be pointed out.
[0046] The embodiment of FIG. 3 is composed of a spinning apparatus 1 , a cooling apparatus 2 , a dividing apparatus 13 , a drawing apparatus 3 , a bulking apparatus 4 , and a winding apparatus 5 . The spinning apparatus 1 comprises three separate spinning pumps 15 . 1 , 15 . 2 , and 15 . 3 . Each of the pumps 15 . 1 , 15 . 2 , and 15 . 3 is connected, via a melt intake 14 . 1 , 14 . 2 , and 14 . 3 to separate melt sources. Each of the melt sources, preferably extruders, produce polymer melts which are different in their properties, composition, or type. Thus, for example, three differently dyed polymer melts could be fed to the individual spinning pumps 15 . 1 , 15 . 2 , and 15 . 3 . However, it is also possible to connect all the spinning pumps to one melt source in order, for example, to produce several monocolor yarns in parallel.
[0047] For extruding the three different polymer melts to form a filament sheet, the ring spinneret 17 is divided on the underside of the nozzle holder 16 into several segments of rings of holes with associated separate diffuser chambers. In FIG. 4 , a view of the ring spinneret 17 is represented. The nozzle plate 20 of the ring spinneret 17 comprises a total of nine segments 25 . 1 to 25 . 9 of rings of holes formed side by side, said segments each containing a plurality of nozzle holes 24 . Intervals are formed between the nozzle holes 24 of the segments 25 . 1 to 25 . 9 of rings of holes. To each of the segments 25 . 1 to 25 . 9 of rings of holes a separate diffuser chamber 21 . 1 to 21 . 9 is assigned.
[0048] The separation of each of the diffuser chambers 21 . 1 to 21 . 9 is formed by a separating wall which is represented as a dashed line in FIG. 4 . The diffuser chambers 21 . 1 to 21 . 9 are connected via a melt diffuser 18 ( FIG. 3 ) to the three spinning pumps 15 . 1 , 15 . 2 , and 15 . 3 . Here the segments 25 . 1 to 25 . 9 of rings of holes form a total of three groups in which the three differently dyed polymer melts are extruded side by side as a segment-like filament sheet. For this, for example, the spinning pump 15 . 1 could be connected, via the melt diffuser 18 , to the diffuser chambers 21 . 1 , 21 . 4 , and 21 . 7 . The spinning pump 15 . 2 could be connected, via the melt diffuser 18 , to the diffuser chambers 21 . 2 , 21 . 5 , and 21 . 8 , and the spinning pump 15 . 3 could be connected, via the melt diffuser 18 , to the diffuser chambers 21 . 3 , 21 . 6 , and 21 . 9 . Assigned to the diffuser chambers 21 . 1 to 21 . 9 , the segments 25 . 1 to 25 . 9 of rings of holes accordingly extrude the different polymers in three groups with the same assignment.
[0049] The extruded filaments 6 of all the segments 25 . 1 to 25 . 9 of rings of holes are drawn off from the spinning apparatus 1 in common in an annular arrangement as filament sheet 7 . Along with this, a cool air flow produced by a blowing means 19 is blown from the inside outwards through the filament sheet 7 . After the solidification of the individual filaments of the filament sheet 7 , the filaments which were extruded from a segment 25 . 1 to 25 . 9 of rings of holes are consolidated, via the dividing apparatus 13 , to form a yarn. Thus a total of nine yarns 8 . 1 to 8 . 9 running in parallel are formed from the annular filament sheet 7 .
[0050] The yarns 8 . 1 to 8 . 9 are drawn in parallel side by side by the stretching apparatus 3 and fed into the bulking apparatus 4 . Within the bulking apparatus 4 , three yarns extruded from different polymer melts are consolidated to form one composite yarn. Thus, three bulked composite yarns 9 . 1 to 9 . 3 are formed from the yarns 8 . 1 to 8 . 9 . For this, for example, all three yarns can be compressed together via a texturing nozzle to form a yarn plug. The yarn plug is then subsequently undone to form a composite yarn. A bulking apparatus of this type is known, for example, from DE 197 46 878 A1. There is however also the possibility of bulking the yarns separately so that the bulked individual yarns are consolidated, e.g. by an intermingling apparatus, to form a composite yarn, as is known from EP 1 035 238 A1.
[0051] Each of the composite yarns 9 . 1 , 9 . 2 , and 9 . 3 is subsequently wound into a package 10 . 1 , 10 . 2 , and 10 . 3 .
[0052] Represented in FIG. 3 , the embodiment of the apparatus according to the invention is suitable in particular for applying the process according to the invention to the production of so-called tricolor yarns.
[0053] In the embodiments represented in FIG. 1 and FIG. 3 the cooling apparatus is formed by a cylindrical blowing means 19 which produces a radial flow of blown air. The cool air can be fed via the nozzle holder or via the opposite end of the blowing means. The blowing wall facing the filament sheet could, for example, be formed of a hollow, cylindrical, seamless, perforated metal sheet. Particularly advantageous is the formation of the blowing means as a blowing plug which comprises a porous jacket of a non-woven, foam, sieve fabric, or a sintered material. A blowing plug of this type is known, for example, from EP 1 231 302 A1. Cooling apparatus of this type are distinguished by the fact that a radial cool air flow is produced which is very uniform over the entire circumferential surface of the blowing plug.
[0054] Furthermore, it is to be noted that the components in the embodiments according to FIGS. 1 and 3 are exemplary in the structure of the spinning apparatus. Thus, for a spinneret subdivided into several segments and having several diffuser chambers, one spinning pump could be assigned to each of the diffuser chambers so that one spinning pump is assigned to each yarn.
[0055] In FIG. 5 , represented in schematic form, is an additional embodiment of the apparatus according to the invention, in which apparatus the known blowing plug is used. For the description of the blowing plug reference is made at this point to EP 1 231 302 A1.
[0056] In the illustrated embodiment the blowing plug 26 is held by its upper end on the nozzle holder 16 . At the opposite end of the blowing plug 26 the air intake 27 is positioned. Here a cool air flow is conducted into the interior of the blowing plug 26 via a holding apparatus 39 . On the circumferential surface of the holding apparatus 39 a preparation apparatus 28 is provided. The preparation apparatus 28 comprises an encircling preparation ring 29 which is attached to a preparation intake 40 . The preparation ring 29 comprises on its surface a preparation means, where the filament sheet 7 produced by the ring spinneret 17 is fed into contact with the preparation ring 29 . Due to this there is a uniform preparation of the individual filaments 6 . To extrude the filament sheet 7 the spinning apparatus 1 may have a structure identical to the embodiment example according to FIG. 1 . To that extent reference is made to the description relating to FIG. 1 .
[0057] To divide the annular filament sheet 7 a dividing apparatus 13 is disposed below the cooling apparatus 2 , the dividing apparatus being formed by several yarn feeders 30 . 1 , 30 . 2 , and 30 . 3 disposed, in a plane of the yarn path, side by side at a distance from one another. The filament sheet 7 is divided by the yarn feeders 30 . 1 , 30 . 2 , and 30 . 3 into three yarns 8 . 1 , 8 . 2 , and 8 . 3 . The yarns 8 . 1 , 8 . 2 , and 8 . 3 are fed in parallel to a pretreatment apparatus 31 . The pretreatment apparatus 31 could comprise one or more processing units in order, for example, to carry out a drawing off, an intermingling, or an additional preparation on the yarns 8 . 1 to 8 . 3 . Thus, the pretreatment apparatus 31 preferably comprises a godet with a roller in order to draw the yarn sheet or the filament sheet off from the spinning apparatus.
[0058] After the pretreatment in the pretreatment apparatus 31 there is a drawing of the yarns 8 . 1 to 8 . 3 fed in parallel side by side. For this, two godet units 32 and 33 are disposed consecutively for a stretching apparatus 3 . The godet units 32 and 33 are each formed from a driven godet and a roller or of two driven godets. For drawing the yarn the godet units 32 and 33 are driven at a predefined differential speed so that the yarns 8 . 1 to 8 . 3 acquire a predefined drawing.
[0059] After the drawing, the yarns 8 . 1 to 8 . 3 are treated by the bulking apparatus 4 so that each forms a bulked yarn. For this, the bulking apparatus 4 comprises three texturing nozzles 34 . 1 , 34 . 2 , and 34 . 3 disposed side by side. Each of the texturing nozzles 34 . 1 to 34 . 3 has the same structure and each is connected to a compressed air source. Within the texturing nozzles 34 . 1 to 34 . 3 the yarns 8 . 1 to 8 . 3 are each consolidated to form a yarn plug 36 . 1 to 36 . 3 . To convey and consolidate the yarns a hot medium is preferably used so that the yarn plugs 36 . 1 to 36 . 3 are stored for cooling on a subsequently disposed cooling drum 35 of the bulking apparatus 4 . A bulking apparatus of this type is, for example, known from EP 1 146 151 A2 so that reference is made thereto for a more detailed description.
[0060] The yarn plugs 36 . 1 , 36 . 2 , and 36 . 3 are each undone after the cooling to form a bulked yarn, drawn off by the subsequent treatment apparatus 37 , and fed to the winding apparatus 5 . The subsequent treatment apparatus 37 could also contain several units for subsequent treatment of the yarns such as, for example, intermingling apparatus, godets, and/or preparation apparatus. Depending on the type of the BCF yarn to be produced, different pretreatments in the pretreatment apparatus 31 and different subsequent treatments in the subsequent treatment apparatus 37 can thus be carried out. The BCF yarns are subsequently wound into the packages 10 . 1 to 10 . 3 .
[0061] In the embodiment of the invention represented in FIG. 5 , the filament sheet 7 fed as a ring is divided to form several yarns fed in a plane of the yarn path. However, there is, in principle, the possibility of first dividing the annular filament sheet into an annular fed yarn sheet. For this, an embodiment of a dividing apparatus 13 is shown in FIG. 6 . The dividing apparatus 13 is formed by a diffuser ring 38 , to which several yarn feeders disposed at a distance from one another are fastened. The diffuser ring 38 comprises in total 6 yarn feeders 30 . 1 to 30 . 6 . Thus the annular filament sheet 7 can be divided into six individual yarns 8 . 1 to 8 . 6 . Particularly advantageous is a division of this type in which the yarns are treated individually in parallel side by side. However, it is also possible to feed the yarns after their division into a yarn path plane aligned in an arbitrary manner to the spinning apparatus.
[0062] The embodiments according to FIGS. 1, 3 , and 5 , of the apparatus according to the invention and the process according to the invention are distinguished in particular by a high performance in the production of qualitatively high-value BCF yarns. Thus, large filter surfaces for the realization of high throughputs can be achieved with the ring spinnerets. The preferably essentially closed annular arrangement of the individual extruded filaments to form a filament sheet permits, with a cool air flow directed in the radial direction, a uniform solidification of the filaments so that each of the filaments has essentially the same physical properties. In principle, it can be mentioned at this point that the cool air could also be directed from the outside inward. For this, the blowing means is attached to a suction apparatus.
[0063] Through the segment-like division of the filament sheet the number and the type of yarns can be flexibly structured in a simple manner. The process according to the invention is thus suitable for monocolor as well as for multi-color yarns, which can be used in particular for the production of flat structures, preferably carpets.
[0064] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A process and apparatus for producing BCF yarns, in which a plurality of strand-like filaments are extruded, cooled, and combined into several yarns. The filaments are extruded in the form of a downwardly advancing annular filament sheet, and the filaments in the sheet are cooled by directing a cool air flow radially through the annular sheet. The sheet is divided into segments and the filaments of each segment are gathered to form a multifilament yarn, and each yarn can then be drawn and bulked, and finally wound into a package. | 3 |
This is a continuation of co-pending application Ser. No. 07/567,243, filed on Aug. 13, 1990, now abandoned.
BACKGROUND OF THE INVENTION
Drug Absorption
Drugs must reach their targets selectively and controllably if their desired pharmacological activities are to be maximized. One approach to optimizing the activities of drugs is to control and sustain their delivery into the systemic blood circulation. Orally administered drugs are generally absorbed in the intestine. Such drugs undergo first pass clearance by the liver and small intestine; that is, they are converted by the intestine and the liver to pharmacologically inactive metabolites and/or are secreted into bile by the liver, either as drug or as active metabolites. As a result, the amount of an orally administered drug actually entering the systemic circulation can be much less than the amount administered. To ensure that effective quantities of such a drug will enter the circulation and reach the targeted site(s) in the body, larger quantities than actually needed must be administered and often must be given in several smaller doses, rather than one dose. Orally administered drugs also typically have poor bioavailability. For example, they may be adversely affected by the pH and the enzymatic activity of the stomach and intestine and may be poorly dissolved in the stomach and intestinal fluids.
There have been numerous attempts to address these problems and to improve the bioavailability of orally administered drugs. The efficacy of some drugs given orally has been improved by administering them with a triglyceride or neutral fat. Such fats represent an environment that is compatible with lipophilic drugs, i.e. that exhibit low aqueous solubility. Fats also enhance the stability of drugs which are unstable in the stomach and intestine. The end products of fat digestion are absorbed by the villi of the intestinal mucosa into a lymphatic vessel, the central lacteal; absorption occurs within a region of the intestine in which limited drug metabolism occurs. The absorbed fat is transported through the thoracic duct, the major lymphatic channel and is subsequently emptied into the blood; it is not carried in the portal blood, which goes to the liver, where first pass metabolism of drugs occurs.
The absorption of griseofulvin has been shown to be enhanced if the drug is co-administered with a high fat content meal or in an oil and water emulsion. Crounse, R. G., Journal of Investigative Dermatoloqy, 37:529 (1961); Carrigan, P. J. and Bates, T. R., Journal of Pharmacological Science, 62:1476 (1973). If the hormone testosterone undecanoate is administered in a peanut oil solution, it is more biologically active than if it is administered in an aqueous microcrystalline suspension. Coert, A. J. et al., Acta Endocrinol, 79:789 (1975); Hirschhauser, C. et al., Acta Endocrinol, 80:179 (1975). This effect is presumed to be due to absorption of the steroid via the thoracic lymph rather than the portal blood; in this way, first pass clearance by the liver is avoided.
Cholesterol, its esters as well as triglyceride constituents (e.g., fatty acids and monoglycerides) are absorbed via the thoracic lymph. The effects of some of these compounds, alone or in the presence of bile salts, upon absorption of some orally administered drugs have been evaluated. For example, oral administration of ubidecarenone, which is used for treating hypertension, in a mixture containing fatty acids having 12-18 carbon atoms and monoglycerides containing such fatty acids, resulted in somewhat greater absorption of the ubidecarenone than occurred after oral administration of the drug along (8.3% v. 2.3%). Taki, K. and Takahira, H., U. S. Pat. No. 4,325,942 (1982). If the steroid progesterone is administered orally in combination with cholesterol or its esters, good sustained biological activity can be obtained. This is believed to be due to the absorption of progesterone via the thoracic lymph and not via the portal circulation. Kincl, F. A., Proceedings of the 6th International Congress of Pharmacology, 5:105 (1975).
Yesair has evaluated the effect of fatty acids having 12-18 carbon atoms, monoglycerides of these fatty acids, and bile salts on the absorption of orally administered estradiol, which is an estrogenic hormone. Yesair, D. W., PCT WO 83/00294 (1983). The mole ratio of fatty acids:monoglycerides:bile salts evaluated ranged from 10:1:1, 1:1:10 or 1:10:1. The preferred ratio was stated to be 2:1:2, which is similar to the micellar composition resulting from the enzymatic digestion of triglycerides in the intestine, which occurs in the presence of bile salts and calcium ions. When excess bile salts are present, estradiol incorporated into the 2:1:2 composition can migrate or partition into a bile salt-enriched micellar solution. This migration or partitioning of estradiol occurred prior to absorption of the drug, as shown by the fact that the initial concentrations in plasma of estradiol are initially greater than those in lymph. In addition, about 25-50% of the estradiol administered in the composition was co-absorbed with the lipid constituents and entered the systemic circulation via the thoracic lymph.
The presence of bile salts, which are absorbed in the ileum (and not in the jejunum, as is most fat) compromised the co-absorption of estradiol with fat by enhancing the migration of the drug from fat to the bile salt micelle. Phosphatidylcholine was used in an effort to maintain the estradiol within the micellar composition in which fatty acids:monoglycerides:bile salts occurred in a 2:1:2 molar ratio. In the presence of excess bile salts, about 60% of the estradiol incorporated into the 2:1:2 micellar composition remained associated with it when phosphatidylcholine was not present. Under the same conditions, about 70-75% of the estradiol remained in the composition when phosphatidylcholine was used. Addition of phosphatidylcholine for this purpose, however, results in an increased size of the delivery system. Size is an important parameter in the absorption of lipid micelles and this effect of phosphatidylcholine might interfere with co-absorption of the drug with the lipids. In addition, excess phosphatidylcholine has been shown to reduce lipid absorption. Ammon, H. V., et al., Lipids, 14:395 (1979); Clark, S. B., Gastrointestinal Physiology, 4:E183 (1978).
Others have also described the effects of the presence of bile salts in lipid formulations used for co-absorption of drugs. Wilson, T. H., In: Intestinal Absorption, Saunders, (1962); Lack, L. and Weiner, I. M., American Journal of Physiology, 240:313, (1961); H. V. Ammon et al., Lipids, 14:395 (1979). For example, little difference in the absorption of 5-fluorouracil (5FU) in the stomach or small intestine was evident when the 5FU was administered alone or in a monoolein/sodium taurocholate mixed micelle formulation. 5FU absorption in the large intestine was greater when the drug was administered in the formulation than when it was administered alone. Streptomycin is poorly absorbed from the intestine. Muranushi and co-workers report that mixed micelles, composed of bile salts, monoolein or unsaturated fatty acids, did not improve the absorption of streptomycin from the small intestine but markedly enhanced the absorption from the large intestine. The enhancement in the large intestine was attributed mostly to the alteration of the mucosal membrane permeability by monoolein or unsaturated fatty acids. In contrast, mixed micelles of bile salts and saturated fatty acids produced only a small enhancement in streptomycin absorption even from the large intestine. Muranushi, N. et al., Journal of Pharmaceutics, 4:271 (1980). Taniguchi et al report that monoolein/taurocholate or oleic acid/taurocholate promotes the absorption of heparin, which is poorly absorbed when administered alone. Taniguch, K. el at., International Journal of Pharmaceutics, 4:219 (1980). Absorption of heparin from the large intestine was twice that which occurred from the small intestine. The concentration of heparin in the mixed micelle to produce the potentiation in the large intestine was approximately one-fourth that required in the small intestine.
In U. S. Pat. No. 4,156,719, Sezoski and Muranishi describe a micelle solution for rectal administration of water-soluble drugs that are poorly absorbed. The composition consists of fatty acids having 6-18 carbons, and/or mono- or diglycerides having the same type of fatty acids; a bile salt or other non-ionic surface activity agent; and water. A lysophosphatidylcholine moiety can be substituted for the fatty acids and mono- or diglycerides. Absorption of streptomycin and gentamycin from the rectum and large intestine is reported to be comparable when the drug is administered in a bile salt:mixed lipid micelle. Similar formulations were not effective in increasing absorption in the duodenum. Muranushi, S. et al., International Journal of Pharmaceutics, 2:101 (1979). Absorption of the two drugs via the rectum and large intestine was markedly greater than that of a comparable dose administered duodenally, even when the mixed lipid micelle concentration administered duodenally was four times that administered via the other routes.
In a patent to the present inventor (U. S. Pat. No. 4,874,795, Yesair) it was shown that a lipid composition with specific lipid components in a prescribed relationship to each other was effective in delivering drugs to the systemic circulation. The lipid composition included fatty acids having 14-18 carbon atoms, monoglycerides with a fatty acid moiety having 14-18 carbon atoms, and lysophosphatidycholine with a fatty acid moiety having 14-18 carbon atoms. The fatty acid to monoglyceride molar ratio could range from 2:1 to 1:2 and the mole percent of lysophosphatidylcholine could range from 30.0 to 1.0 when expressed as the mole percent of the total lipid composition. This lipid composition was shown to effectively transport drugs to the systemic circulation when they were incorporated into the lipid composition. The lipid composition also was shown to serve as a source of calories by virtue of its inherent fatty acid content that could be metabolized in an individual's body.
Nutrition
Caloric requirements for individuals are primarily a function of body composition and level of physical activity. Medically compromised, aged and physically stressed individuals often have limited body fat. Consequently, energy (caloric) needs will be satisfied mainly from exogenous sources.
Physical activity uses muscle and the energy requirements of all muscles, including the heart, are met primarily as a result of oxidation of fatty acids, from dietary fat or mobilized adipose fat. Adipose fat can, as noted, be minimal and therefore efficient absorption of fat can be an important consideration in satisfying the energy demands of the medically infirm, the aged and the physically active.
Fat absorption can be compromised in many circumstances. For example, in cystic fibrosis, a disorder of exocrine glands, there is a deficiency of pancreatic enzymes, bile salts and bicarbonate ions. Nutrition Reviews, 42:344 (1984); Ross, C. A., Archives of Diseases of Childhood, 30:316 (1955); Scow, R. O. E., Journal of Clinical Investigation. 55:908 (1975). Fat absorption in cystic fibrosis patients can be severely affected and 30 to 60 percent of ingested fat can be malabsorbed. The malabsorption and resulting steatorrhea are generally not successfully handled by the oral administration of pancreatic lipase. In an effort to control the steatorrhea, the patient may consume less fat than desirable for good health.
Fat absorption can be compromised under stressful conditions and the generally accepted way of addressing this problem has been to reduce fat consumption. This approach can result in both acute and chronic medical problems. These problems might be avoided, or at least minimized, if a readily absorbable source of fat could be made available.
At the present time, there is a need for a more efficient method of transporting orally administered drugs to the systemic circulation. This need is particularly important for individuals with impaired oral intake, intestinal absorption or diminished transport capacity. At the same time, there is a need for a more efficient oral administration of calorically rich substances, especially to individuals with acute energy requirements. The achievement of such increased efficiencies would promote more effective drug therapies and nutritional stability.
SUMMARY OF THE INVENTION
This invention relates to compositions for providing at least one drug or for providing readily absorbable calories to an individual. The basic composition of the present invention is comprised of: (1) at least one non-esterified fatty acid having 14-18 carbon atoms, (2) at least one monoglyceride which is a monoester of glycerol and a fatty acid having 14-18 carbon atoms, (3) lysophosphatidylcholine in which the fatty acid moiety has 14-18 carbon atoms, and (4) bicarbonate. An optional fifth component of the composition is bile salts, which can be added to the other four components of the basic composition. The composition of the present invention is in the form of mixed lipid colloid particles, since they form a colloidal suspension in an aqueous environment. In those instances in which components (1) through (4) are present in a composition, the composition is referred to as a mixed lipid-bicarbonate composition (i.e., a mixed lipid- bicarbonate colloid) and in those instances in which components (1) through (4) plus bile salt are present, the composition is referred to as a mixed lipid-bicarbonate-bile salt composition (i.e., a mixed lipid-bicarbonate-bile salt colloid). The bile salt component is added when it is desired to further reduce the size of the particulate form of the basic composition from its inherent colloidal size.
In both types of compositions, the non-esterified fatty acid and the esterified fatty acid moieties of the monoglycerides and lysophosphatidylcholine can be saturated or unsaturated. If the non-esterified fatty acids in the composition are saturated, sufficient quantities of divalent cations (approximately one-half the molar amount of the fatty acids), such as calcium ions, can optionally be added to form non-esterified fatty acid salts. These non-esterified fatty acid salts would then form the non-esterified fatty acid portion of the composition.
The non-esterified fatty acids and the monoglycerides are present in the composition in a molar ratio of between about 2:1 and about 1:2 (non-esterified fatty acid:monoglyceride). Taken together, the nonesterified fatty acids plus monoglycerides comprise from about 70.0 mole percent to about 99.0 mole percent of the total lipid composition. The lysophosphatidylcholine therefore comprises from about 30.0 mole percent to about 1.0 mole percent of the total lipid composition.
The components of the composition of the present invention, namely the fatty acids, monoglycerides, lysophosphatidylcholine, bicarbonate, and optionally, bile salts, can be combined to form a mixture before being placed in an aqueous environment. Preferably, however, the fatty acid, monoglyceride and lysophosphatidylcholine lipids of the basic composition are mixed together and then placed in an aqueous environment for the subsequent addition of bicarbonate, and optionally, bile salts. In either instance, following placement of the mixed components in the aqueous environment, the composition is further processed to form the colloidal particles. For example, it can be subjected to a shearing operation, mixed or stirred, sonicated or otherwise subjected to an appropriate force. To achieve these colloidal particles, the lysophophatydylcholine concentration of the lipid components (i.e., the sum of the concentrations of the individual lipid components) should be at least about 0.1 mM to ensure stable, mixed lipid particle formation.
The inclusion of bicarbonate in the basic mixed lipid-bicarbonate composition provides a means for controlling the size of the colloidal particles formed as a result of the intermolecular forces between the components of the composition in an aqueous environment. When the molar ratio of bicarbonate to the lysophosphatidylcholine in the total lipid is about 1.4:1 or less, the mixed lipid-bicarbonate colloidal particle size is approximately 120 nm or larger. When the molar ratio of bicarbonate to the lysophosphatidylcholine in the total mixed lipid increases from about 2:1 to about 7:1, the mixed lipid-bicarbonate colloidal particle size decreases from approximately 120 nm to approximately 70 nm in direct relationship to the increase in molar ratio of bicarbonate to lysophosphatidylcholine in the total mixed lipid. If the molar ratio of bicarbonate to lysophosphatidylcholine in the total mixed lipid is increased beyond about 7:1, there is no further decrease in mixed lipid-bicarbonate colloidal particle size.
When bile salts are additionally incorporated into the lipid-bicarbonate composition, the resulting mixed lipid-bicarbonate-bile salt colloidal particle size is smaller than the mixed lipid-bicarbonate colloidal particle size. For example, if the molar ratio of bicarbonate to the lysophosphatidylcholine in the total mixed lipid is at least about 7:1 and the molar ratio of bile salt to the lysophosphatidylcholine in the total mixed lipid is at least about 10:1, the mixed lipid-bicarbonate- bile salt colloidal particle size is about 10 nm or less.
The compositions of this invention are designed to promote uptake of the mixed lipid colloid of the lipid formulations into the mucosa of the small intestine, subsequent synthesis into chylomicrons, translocation of the chylomicrons to the thoracic lymph and eventual transport to the systemic circulation (i.e., the blood stream). The compositions which are the subject of this invention have several characteristics which will promote rapid and quantitative absorption of lipids in the small intestine and transport of lipids via the lymphatic system. First, the mole ratio range described for the fatty acids and monoglycerides is optimal for their absorption in the jejunum. Second, the unsaturated fatty acids or saturated fatty acid-calcium salts included in the compositions have been shown to be maximally absorbed and preferentially transported via the thoracic lymph rather than via the portal blood. Third, the compositions contain lysophosphatidylcholine which enhances translocation of the lipid particles as chylomicrons into the thoracic lymph. Fourth, the reduction in size of the lipid particles allows the existence of more particles per unit volume and promotes ease of mass transport of the individual particles. This reduction in size of the particles also allows a higher concentration of organized lipid particles to exist in an aqueous environment.
The mixed lipid compositions which are the subject of this invention can serve as a transport vehicle for enhanced uptake and bioavailability of a drug or drugs. Drugs are broadly defined here as any chemical agents or chemical substances which affect living processes. These chemical substances can become integrally incorporated into the basic lipid particles. Examples of substances which can be incorporated into the basic composition of this invention are drugs administered for diagnostic, therapeutic or preventive purposes, lipophilic pro-drugs, bioactive peptides and other xenobiotics. Other such substances include vitamins, e.g., fat-soluble vitamins, and other like materials of metabolic or nutritive value. The enhanced uptake occurs because the substance incorporated into the compositions of this invention is absorbed together with the lipids and subsequently enters the systemic circulation via the lymphatic system. The substance is absorbed more rapidly and more completely than it otherwise would be because first pass clearance by the liver is avoided. Thus, more of the absorbed dose enters the blood and is available to reach target sites within an individual's body than would be available if the mixed lipid-bicarbonate formulations were not used.
The subject compositions can also serve as highly concentrated sources of readily absorbable fat, which can be used, for example, by those individuals in need of a calorically dense dietary component. When used in this manner, the compositions of the present invention generally do not include a drug and are comprised of the nonesterified fatty acids, monoglycerides and lysophosphatidylcholine. They can, for example, include a fat soluble vitamin.
The subject compositions also provide stable mixed lipid colloids that protect incorporated drugs from, for example, enzymatic and chemical degradation in the stomach and upper intestine. In addition, the inherent stability of the lipid components of the compositions make the compositions stable over extended periods of time and thus can serve as stable delivery vehicles for the substances incorporated into the mixed lipidbicarbonate formulations.
The subject mixed lipid compositions can be produced according to the following method: In the preferred embodiment, the method includes the following steps: First, the following components are combined in a non- aqueous environment: (1) at least one non-esterified fatty acid having 14-18 carbon atoms, (2) at least one monoglyceride which is a monoester of glycerol and fatty acid having 14-18 carbon atoms, and (3) lysophosphatidylcholine in which the fatty acid moiety has 14-18 carbon atoms. The non-esterified fatty acids, monoglycerides and lysophosphatidylcholine are mixed together in molar ratios as described above and then placed in an aqueous environment containing the bicarbonate component. Second, the mixed lipid composition is subjected to shearing forces of sufficient energy and for sufficient time for lipid particles of uniform size to form. The shearing forces produce cavitation of the aqueous environment containing the lipid and bicarbonate components such that these components segregate into particles. The results of this shearing operation are mixed lipidbicarbonate colloidal particles of a homogeneous, uniform size.
The shearing forces may be applied as the bicarbonate is being added to the mixed lipid-aqueous mixture or they can be applied after the bicarbonate has been added to achieve a specified molar ratio of bicarbonate to total mixed lipid. In either case, the same mixed lipid-bicarbonate colloidal particle size results.
The same method is used to produce the mixed lipid-bicarbonate-bile sale compositions of the present invention. Again, the bile salt can be added before or during the shearing operation. The same mixed lipidbicarbonate-bile salt colloidal particle size is achieved in either occurrence.
The bicarbonate and bile salt can be added to the lipid mixture in the aqueous environment either simultaneously or sequentially. The order in which they are added is not critical. The same uniform mixed lipid-bicarbonate-bile salt colloidal particle size is achieved regardless of which order the bicarbonate and bile salt are added. To achieve the 10 nm or less mixed lipid-bicarbonate-bile salt colloidal particle size, the proper molar ratios of bicarbonate to total mixed lipid and bile salt to total mixed lipid must be attained before the final shearing operation.
The above identified lipid particles can also be formed when biologically compatible surfactants, such as TWEEN 80, are added to the above formulations. The addition of such surfactants does not impede the formation of the mixed lipid-bicarbonate or mixed lipid-bicarbonate-bile salt colloidal particles.
A drug or drugs can be administered to an individual by oral administration of a mixed lipid-bicarbonate composition of the present invention in which the drug (or drugs) is incorporated. Likewise, calories in the form of fatty acids, monoglycerides or lysophosphatidylcholine can be delivered to individuals by orally administering the above mixed lipid-bicarbonate compositions. In either case, bile salts can optionally be a component of the mixed lipid bicarbonate composition to form mixed lipid-bicarbonate-bile salt compositions that can be administered orally to an individual.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the relationship between the surface tension of the mixed lipid formulation and the molar concentration of the lysophosphatidylcholine (and mixed lipids) in the mixed lipid formulation.
FIG. 2 is a graph showing the relationship between the particle size or surface tension of the mixed lipid formulation and the amount of sodium bicarbonate in the aqueous environment.
FIG. 3 is a graph showing the relationship between the particle size of the mixed lipid formulation and the amount of bile salt, sodium taurocholate, in the aqueous environment.
FIG. 4 is a graph showing the relationship between the particle size or surface tension of the mixed lipid formulation and the combination of bicarbonate and bile salt, sodium taurocholate.
FIG. 5 is a graph showing the elution profiles from a Sepharose 4B column of the mixed lipid (fenretinamide)-bicarbonate, mixed lipid(fenretinamide)bicarbonate-bile salt and of free fenretinamide.
FIG. 6 is a graph showing the elution profiles from a Sepharose 4B column of the mixed lipidbicarbonate formulation and the mixed lipid-bicarbonate-bile salt formulation containing diltiazem (Drug A) and hydrochlorothiazide (Drug B).
DETAILED DESCRIPTION OF THE INVENTION
The composition of the present invention is comprised of non-esterified fatty acids, monoglycerides of those fatty acids, lysophosphatidylcholine having those fatty acids as their fatty acid moiety, and bicarbonate. The selection of the components of the subject composition is based on the absorption and transport characteristics of the fatty acids, the contribution of lysophosphatidylcholine to solubilization of drugs in the lipid composition, the properties of bicarbonate that allow stable, submicron size lipid-containing particles to exist and to translocation of absorbed fat into the lymph (rather than into the portal circulation).
Absorption of saturated fatty acids has been shown to be inversely related to the number of carbon atoms in the fatty acid. For example, absorption of decanoic (10:0, which denotes chain length and degree of unsaturation) is almost quantitative. For lauric (12:0), it is more than 95%; for myristic (14:0), 80-90%; for palmitic (16:0), 65-70% and for stearic (18:0), 30-45%. Absorption of unsaturated fatty acids into lymph (e.g., linoleic 18:2) have been shown to be more rapid and to a greater extent than are saturated fatty acids. Taniguchi, K., International Journal of Pharmaceutics, 4:219 (1980).
Transport of absorbed fatty acids via the lymph (and not in the portal circulation) varies greatly. That is, a much larger percentage of absorbed unsaturated fatty acids has been shown to be carried in the lymph than is the case for saturated fatty acids. About 85% of unsaturated fatty acids has been shown to be carried in the lymph. Miura, S. et al., Keio Journal of Medicine, 28:121 (1979). The amount of these absorbed fatty acids being carried in the lymph is also inversely related to chain length: 68-80% for myristic; 85% for palmitic and stearic.
If saturated fatty acids are included in the composition of this invention, they can be included as calcium salts or salts of another cation. This is true because the enzymatic hydrolysis of triglycerides, which releases saturated fatty acids, favors their calcium soap formation. Tak, Y. A. and Grigor, M. R., Biochimica Biophysica Acta, 531: 257 (1978).
Translocation of absorbed fat into the lymph has been shown to require lysophosphatidylcholine. The rate, but not the magnitude, of the translocation of absorbed fat is apparently related to the fatty acid moiety of the lysophosphatidylcholine. For example, oleoyl lysophosphatididylcholine results in a 100% increase in triglyceride and phospholipid in lymphatic transported fat when compared with the effects of a lysophosphatidylcholine derived from a phosphatidylcholine composed mainly of saturated fatty acids (e.g., palmitic, C16:0; stearic, C18:0). Incorporating an unsaturated lysophosphatidylcholine into the compositions of this invention will enhance the translocation of the absorbed lipids and the co-absorbed drugs or other substances. In addition, lysophosphatidylcholine plays a role in the solubilization of some drugs (i.e., its presence enhances the solubility of the drugs in the compositions).
Examples of unsaturated fatty acids which can be used in the composition of this invention are:
______________________________________palmitoleic C.sub.16 H.sub.30 O.sub.2 16:1oleic C.sub.18 H.sub.34 O.sub.2 18:1linoleic C.sub.18 H.sub.32 O.sub.2 18:2linolenic C.sub.18 H.sub.30 O.sub.2 18:3______________________________________
Examples of saturated fatty acids which can be used in the subject composition are:
______________________________________myristic C.sub.14 H.sub.28 O.sub.2 14:0palmitic C.sub.16 H.sub.32 O.sub.2 16:0stearic C.sub.18 H.sub.36 O.sub.2 18:0______________________________________
The unsaturated and saturated fatty acids can be present individually or in combination. That is, the fatty acid constituents of one or more of the lipid components (fatty acid, monoglyceride and lysophosphatidylcholine) can be identified or they can be a mixture of the unsaturated and/or saturated members of the preferred fatty acid families.
The non-esterified fatty acids and monoglycerides are present in amounts which result in a molar ratio of from about 2:1 to about 1:2 (non-esterified fatty acid: monoglyceride).
In addition, the compositions have lysophosphatidylcholine, the fatty acid moiety of which has 14-18 carbon atoms and is preferably unsaturated. The fatty acid constituent of the lysophosphatidylcholine is preferably one of those listed above. The quantity of lysophosphatidylcholine in the composition is determined by the amount needed for enhanced solubilization of a drug to be administered in the composition and the amount needed for its role in translocation. In general, lysophosphatidylcholine choline comprises from about 1.0 mole % to about 30.0 mole % of the total composition. The fatty acids which comprise the compositions of this invention--whether as nonesterified fatty acids or as constituents of monoglycerides or lysophosphatidylcholine--can all be the same or a number of different ones can be included.
Lipid formulations including the fatty acids, monoglycerides and lysophosphatidylcholine described above will swell in the presence of distilled water when heated and hand-shaken. Eventually, a gelatinous matrix is yielded that appears to be crystalline when viewed under a polarizing microscope. In the presence of 0.1 N HCl or pH 7.0 phosphate buffer, these lipid formulations do not appear to swell in the presence of distilled water when heated and hand-shaken, but remain as large oil/solid particles in these solutions. In contrast, these lipid formulations in the presence of distilled water and aqueous bile salts, with heat and hand-shaking, yield micron sized particles when viewed under a polarizing microscope. A conclusion that can be drawn from these observations is that the ionic species in the aqueous medium affect the size and constitution of particles formed from these lipid formulations. In particular, the anion types can significantly alter lipid particle formation, constitution and size.
It is known that, in addition to bile salts, the principal anion in the upper region of the small intestine is bicarbonate. It has been found that when this anion is present in sufficient quantities in the aqueous medium of the lipid formulations, submicron particles can be formed. The bicarbonate is incorporated in the compositions of the present invention by directly mixing the bicarbonate with the lipid components, or, preferably, by dissolving salts of this anion, such as sodium bicarbonate, potassium bicarbonate, etc., in the aqueous environment to which the previously mixed lipid components of the compositions have been placed. When the mixed lipid colloidal particles are formed by the shearing operation, bicarbonate is integrally included in the particulate form of the compositions.
If bile salts are additionally present in sufficient quantities in the aqueous environment, the already submicron particles can be even further reduced in size. Examples of bile salts that will reduce the size of the mixed lipid-bicarbonate colloidal particles are sodium taurocholate and sodium glycocholate. The bile salts can be added to the non-aqueous mixed lipid-bicarbonate mixture, or, preferably, are added to the aqueous environment in which the lipid components and bicarbonate have been combined. The bile salts then become incorporated in the colloidal particles of the compositions when these particles are formed by the shearing operation.
The compositions of this invention are preliminarily made according to the following method. The component lipids are weighed and mixed, with or without heat, to attain liquid homogeneity. When a drug is incorporated, it is added and dissolved, with or without heat, in the lipid mixture. A uniform state is indicated by the absence of any solids at the appropriate temperature for the mixture to be a liquid and by the absence of any schleiren. A schleiric effect will be more apparent at greater concentrations of the drug in the lipid mixture if it is included. The formulation is stable to several freeze-thaw cycles; the appearance of solids or schleirin may indicate instability of the formulation.
A second preliminary method of making the formulation involves dissolving the component lipids and drug, if it is incorporated, in a solvent or mixture of solvents and mixing to attain homogeneity. The solvents are removed, in vacuo or by other suitable methods. The criteria for a suitable formulation are the same as noted above.
A desired amount of an above preliminary formulation is placed in an aqueous environment. This aqueous environment is predominately water. Other substances can be present without altering the basic compositions. Examples of these other substances are pH buffering materials, amino acids, proteins, such as albumin or casein, and viscosity enhancers such as xanthine gums or gum arabic. The only criterion for the presence of these other substances is that they not substantially interfere with or alter the forces which cause the individual components of the composition to form the colloidal particles of the composition.
Bicarbonate is added to the aqueous environment by dissolving a desired amount of bicarbonate salt in the aqueous environment either before or after the preliminary formulation has been placed there.
The component lipid mixture in the aqueous environment is then subjected to shearing forces by an appropriate means. Typically, these shearing forces are achieved with a sonicator or a microfluidizer. The shearing operation is performed at an appropriate energy and for a time sufficient to yield homogeneous lipid-containing particles of the desired size. As noted in a below exemplification, the amount of bicarbonate relative to the amount of lipid formulation is important in determining the ultimate size of the mixed lipid-bicarbonate colloidal particles. Below a molar ratio of 1.4:1 (bicarbonate:mixed lipid formulation) the mixed lipid bicarbonate colloidal particle size will be larger than approximately 120 nm. Between a molar ratio of 1.4:1 and 7:1, the mixed lipid-bicarbonate colloidal particle size will be between approximately 120 nm and approximately 70 nm, depending on the molar ratio of bicarbonate to mixed lipid formulation. The bicarbonate can be added gradually or all at one time as the shearing procedure is performed. Alternatively, the bicarbonate can be added before the shearing procedure is performed.
To obtain smaller submicron particles, bile salts at an appropriate molar ratio (bile salt:mixed lipid formulation) can be added to the aqueous medium before, concurrently, or after the bicarbonate is added. The molar ratios of bile salt to mixed lipid formulation as well as bicarbonate to mixed lipid formulation can be any independent value, provided each of them is at least about 1:1 (i.e., the bile salt concentration or the bicarbonate concentration should be at least the same as the mixed lipid concentration). That is, the bile salt:mixed lipid formulation molar ratio as well as the bicarbonate:mixed lipid formulation molar ratio can be independently changed, resulting in an accompanying change in the mixed lipid-bicarbonate-bile salt colloidal particle size. However, to achieve mixed lipid-bicarbonate-bile salt colloidal particles of 10nm or less, the molar ratio of bile salt to mixed lipid formulation should be at least about 10:1 and the molar ratio of bicarbonate to mixed lipid formulation should be at least 7:1. Again, the bile salts can be added gradually or all at one time before or while the shearing operation is performed.
As previously noted, compositions of the present invention can also include a drug, which is any chemical agent or chemical substance which affects living processes. They include, but are not limited to, drugs administered for diagnostic, therapeutic or preventive purposes; lipophilic pro-drugs; nutrients, such as fat soluble vitamins, and other xenobiotics.
Biologically compatible surfactants can be added at any time to the aqueous medium containing the lipid formulation and bicarbonate (optionally also containing the bile salt). Examples of biologically compatible surfactants include TWEEN 20, TWEEN 80, etc. These surfactants can be added before or after the shearing operation.
The mixed lipid-bicarbonate or the mixed lipidbicarbonate-bile salt colloidal particles are stable and can be stored under normal storage conditions. When a drug is incorporated in either of these compositions, the colloidal particles serve as a vehicle for transporting the drug to the intestinal mucosal cells following oral administration of the drug-containing particles to an individual. These drug-containing colloidal particles can be packaged, for example, in individual containers for oral administration of specific dosages of the incorporated drug. An individual simply opens the packaging container and swallows its contents to achieve the oral administration of the drug-containing colloidal particles.
Likewise, the mixed lipid-bicarbonate or the mixed lipid-bicarbonate-bile salt compositions can serve as a source of calories when administered without an incorporated drug. Again, an individual simply swallows the contents of a container that has a specific amount of the mixed lipid formulation to achieve oral administration of the desired composition.
The mixed lipid-bicarbonate or the mixed lipid-bicarbonate-bile salt compositions, with or without a constituent drug, also can be topically applied to the skin of an individual. Such application provides a source of lipids, and drug if included, to the skin surface for whatever purpose is desired.
The present invention is illustrated by the following examples which are not intended to be limiting of the invention.
EXAMPLE 1
Formation of Submicron Sized Particles of Lipid Formulations
The following lipids were mixed together to yield a non-aqueous lipid mixture: soy lysophosphatidylcholine (LPC), 18:1 monoolein monoglyceride (MG), and 18:1 oleic acid fatty acid (FA). The sources of these lipids were: Avanti Polar Lipids, 5001A Whitling Drive, Pelham, AL 35124 for LPC, and Nu-Chek-Prep, Inc., P. 0. Box 295, Elysian, MN 56028 for MG and FA. The molar ratio of these lipid components was 1:3:3 for LPC:MG:FA. This non-aqueous lipid mixture was put into water at LPC concentrations ranging from 10 -3 to 1 mM. Since the molar ratio of LPC:MG:FA was 1:3:3, the total lipid mixture molar concentrations also ranged from 10 -3 to 1 mM in the water environment. These formulations were then subjected to probe sonication (Cole-Parmer, 4710 Series with a S&M 10 86 tip, 1.25 minutes at full power output). The surface tension (dynes/cm) of these mixed lipid formulations was measured by determining the time between drops. Using this technique, the critical micelle concentration of this mixed lipid formulation was found to be about 0.1 mM (See FIG. 1).
Particle sizes were measured of a 1.5 mM concentration of LPC (and also total lipid mixture) of the 1:3:3 LPC:MG:FA formulation in water after probe sonication was performed. The particle sizes were measured with either a Nicomp Analyzer or a Brookhaven Particle Sizer. After the initial probe sonication, the particle size was approximately 170 nm. Sodium bicarbonate, NaHC03, was incrementally added, sonication was continued and particle size was monitored. As the molar ratio of bicarbonate to lipid formulation (bicarbonate:lipid) approached 1.4:1, the particle size approached approximately 120 nm. When the bicarbonate:lipid molar ratio was increased to 7:1, the particle size decreased to approximately 70 nm. Between these bicarbonate:lipid molar ratios, intermediate size particles of the lipid formulation were observed (see FIG. 2). As the bicarbonate:lipid molar ratio was further increased, the particle size did not significantly change.
In another experiment, soy lysophosphatidylcholine, 18:1 monoolein monoglyceride, and 18:1 oleic acid fatty acid from the same sources as in the first experiment were mixed together to yield a non-aqueous lipid mixture with a molar ratio of 1:3:3 LPC:MG:FA. The non-aqueous lipid mixture was put into water so the LPC (and also total lipid mixture)molar concentration was about 1.7 mM. This formulation was then subjected to either probe sonication (Cole-Parmer sonicator) or shearing by action of a Microfluidizer (Model 110T, 2 passes at 70 psi). After the shearing operation, the particle size was approximately 150 nm for the 1:3:3 formulation. The bile salt, sodium taurocholate, was gradually added and shearing was continued. The particle size was monitored as the bile salt was added. The particle size was reduced to approximately 100 nm while the bile salts were in their monomeric state (i.e., less than about 5 mM) and the molar ratio of bile salt to mixed lipid was about 5:1. As more bile salt was added, the particle size for this formulation decreased to approximately 50 nm when the bile salts were primarily in their micellar state (i.e., greater than about 5 mM) and the molar ratio of bile salt to mixed lipid was about 9:1. Between these bile salt:mixed lipid molar ratios, intermediate size particles of the lipid formulations were observed (see FIG. 3).
When bicarbonate was added with sonication to the formulations of the latter experiment, the particle size was further reduced to approximately 10 nm or less as the bicarbonate:lipid molar ratio was increased to at least 7:1. When the bile salt, sodium taurocholate, was added with sonication to the formulation of the second experiment, the particle size was further reduced to approximately 10 nm or less as the bile salt:lipid molar ratio was increased to 10:1, i.e., as the bile salts reached their critical micellar concentration (achieving the micellar state). That is, when both the bicarbonate ion and bile salt reached their optimal concentrations for forming the smallest size particles of the lipid formulations, the particle size was approximately 10 nm or less (see FIG. 4, where the concentration of LPC, and also total lipid mixture, was about 2.7 mM for the 1:3:3 LPC:MG:FA formulation).
EXAMPLE 2
Incorporation of Drugs in the Colloidal Particles
Fenretinamide was formulated with the mixed lipid LpC:MG:FA (1:3:3 molar ratio) using the solvent method of preparation. The molar concentration of fenretinamide was 0.8 with respect to LPC (and also total lipid mixture) in the mixed lipid(drug) formulation. This non-aqueous mixed lipid(drug) formulation was put into an aqueous environment so the LPC (and also total lipid mixture) concentration was about 1.3 mM. The aqueous environment contained either bicarbonate at a concentration of 12.5 mM (i.e. a molar ratio of about 10:1 for bicarbonate:(LPC in mixed lipid) or bicarbonate and bile salt at respective concentrations of 12.5 mM (i.e. molar ratios of 1:10:10 for LPC in mixed lipid:bicarbonate:bile salt). Colloidal particles of this mixed lipid (fenretinamide) with bicarbonate or with bicarbonate and bile salt were made by the method described in Example 1. This drug is hydrophobic in nature and tends to reside in the hydrocarbon region of the mixed lipid-bicarbonate or mixed lipid-bicarbonate-bile salt formulations. Upon size exclusion chromatography on a Sepharose 4B column, the drug remained associated with the mixed lipid-bicarbonate or with the mixed lipid-bicarbonate-bile salt particles (see FIG. 5). Free drug, i.e., without the presence of the particles, eluted from the column with a distinct elution profile in the region identified as `free drug` in FIG. 5. The smaller size of the mixed lipid(drug)-bicarbonate-bile salt particles compared with the the mixed lipid(drug)bicarbonate particles is noted from the longer retention before elution from the size exclusion column.
Diltiazem, a benzothiazepine, was formulated with the mixed lipid LPC:MG:FA (1:3:3 molar ratio) using the solvent method of preparation. Colloidal particles of this mixed lipid(diltiazem) formulation with either bicarbonate or bicarbonate and bile salt were made by the method described in the preceding experiment. This drug is hydrophobic in nature and tends to reside in the hydrocarbon region of the mixed lipid-bicarbonate formulations. Upon size exclusion chromatography on a Sepharose 4B column, the drug remained associated with the mixed lipid-bicarbonate particles as well as with the mixed lipid-bicarbonate-bile salt particles. Free drug, i.e. without the presence of the particles, eluted from the column with a distinct elution profile when compared with the drug associated with the mixed lipid-bicarbonate particles. (See Drug A and `Free Drug` of FIG. 6).
In a separate experiment, hydrochlorothiazide (HCTZ) was formulated with the mixed lipid LPC:MG:FA (1:3:3 molar ratio) using the solvent method of preparation. This drug is not soluble per se with just monoglycerides and fatty acids. However, colloidal particles of this mixed lipid(HCTZ) formulation with bicarbonate were made by the method described in the first experiment of this Example. Size exclusion chromatography of these mixed lipid(HCTZ)-bicarbonate particles on a Sepharose 4B column showed the elution profile of HCTZ as free HCTZ. This indicates that HCTZ probably resides in the polar regions of the mixed lipid-bicarbonate formulations and becomes free drug when bicarbonate is present. Next, the mixed lipid(HCTZ) formulation and mixed lipid(diltiazem) formulation of the preceding experiment were mixed together at about a 1:5 weight ratio of the respective formulations. This `super mixture` was then sonicated in either an aqueous bicarbonate solution or an aqueous bicarbonate-bile salt solution and the resulting materials were eluted by size exclusion chromatogrphy from a Sepharose 4B column. Mixed lipid (diltiazem)-bicarbonate colloidal particles or mixed lipid (diltiazem)- bicarbonate-bile salt colloidal particles (Drug A in FIG. 6) and free HCTZ (Drug B in FIG. 6) were eluted. These results show that with this technique of making mixed lipid(drug)-bicarbonate colloidal particles or mixed lipid(drug)-bicarbonate-bile salt colloidal particles, together with size exclusion chromatography, one can approximate the stability of mixed lipid-drug formulations to the milieu of the GI tract.
EXAMPLE 3
Skin Application of the Colloidal Particles
The mixed lipid formulation of Example 1 was additionally mixed with casein (1-2% casein by weight in the lipid mixture) or with visible or fluorescent dyes. Colloidal particles of mixtures with bicarbonate were made by the method described in Example 1. These colloidal particles were topically applied to the skin. Following this application, the colloid lipids that resided on the skin surface gave a desirable tactile sensability, e.g., softness, and repelled wetting of the skin surface with water. The colloidal particles that contained the visible or fluorescent dyes were solubilized from the skin surface by detergents.
Equivalents
Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such inventions are intended to be encompassed by the following claims. | A composition is disclosed containing non-esterified fatty acids having 14-18 carbon atoms, monoglycerides which are monoesters of glycerol and fatty acids having 14-18 carbon atoms, lysophosphatidylcholine in which the fatty acid moiety has 14-18 carbon atoms and bicarbonate. The compositions can optionally also contain bile salts. These compositions form submicron size colloidal particles and can act as vehicles for transporting orally administered drugs, sources of calories in the form of readily absorbable fats and as particles for topical application to the skin. A method of making these particles is also described. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A "MICROFICHE APPENDIX"
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the disassembly or unthreading of pipe, specifically of oil and gas well drilling pipe and more particularly to an improved method and apparatus for enabling a user to disassemble or destab joints of oil field drill pipe and the like even in offshore marine conditions, e.g. on semisubmersible rigs and the like. Even more particularly, the present invention relates to an improved destabbing apparatus and its method of use wherein a cylindrically shaped sleeve having a hinged body enables the sleeve to be assembled and disassembled to a pair of connected joints of pipe, the lower end of the sleeve having a cam and clamp arrangement that securely fastens the sleeve to the lower of the two pipe joints enabling a user to "destab" (disassemble) the upper joint while the sleeve grips the lower joint.
2. General Background of the Invention
In the oil and gas well drilling industry, it is common to employ drill strings that are comprised of a number of lengths of drill pipe that are connected end to end. In some particular types of joints such as those that employ wedge threads, dovetail threads, taper threads and the like, excess thread wear and thread damage can more easily occur during destabbing operations. Further, rough seas cause floating oil well drilling vessels to pitch so that aligning pipe sections is difficult.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an improved method of destabbing or disconnecting a pair of threadably interengaged and generally vertically oriented oil and gas well drill pipe sections that are connectable end to end at threaded pin and box joint connections.
The method first provides a pair of pipe joints to be joined, each having end portions with mating faces and threaded portions that are connected to similarly threaded portions of another joint.
During destabbing, a sleeve is affixed to the assembly of the pipe joints at the mating faces, wherein a lower end portion of the sleeve engages the lower joint and an upper end portion of the sleeve engages the upper joint.
The joints are then "destabbed" by rotating the upper joint relative to the lower joint and wherein the sleeve tightly engages the lower joint.
During this method, the longitudinal axes of the joints are maintained in alignment. The present invention also provides a pipe destabbing apparatus for disconnecting a pair of threadably connected pipe joints having threaded end portions and mating faces at the end portions.
The apparatus includes a sleeve having a pair of connected sections, means on the sleeve sections for enabling a user to manipulate the sleeve sections during use, at least one of the sleeve section having a window, the lower end of the sleeve having a compressive member for pressing the sleeve against the lower joint of the pair of assembled joint of pipe, and wherein the window enables the user to position the mating faces at the middle of the sleeve by visual inspection.
The upper end of the sleeve closely conforms to the upper joint of pipe and the compressive member applies sufficient load to the assembled joints at the lower joint so that when the two joints are rotated with respect to one another during disassembly or destabbing, the lower joint is affixed to the sleeve and the upper joint rotates with respect to the sleeve and lower joint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a perspective view of the preferred embodiment of the apparatus of the present invention illustrating the destabbing of one joint of pipe from another joint of pipe;
FIG. 3 is a perspective view of the preferred embodiment of the apparatus of the present invention; and
FIG. 4 is a top view of the preferred embodiment of the apparatus of the present invention;
FIG. 5 is a top view of the preferred embodiment of the apparatus of the present invention showing the body in an open position;
FIG. 6 is an elevational view of the preferred embodiment of the apparatus of the present invention; and
FIGS. 7-8 are fragmentary views showing the locking cam position.
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-6 show generally the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. Destabbing apparatus 10 includes a cylindrically shaped sleeve in the form of two semicircular clamp sections 21, 22 as shown in FIGS. 1-4. In the oil and gas well drilling industry, stabbing means to thread one joint of drill pipe that is vertically oriented into another joint of drill pipe that is vertically oriented such as occurs when running a drill string into the well. "Destabbing" refers to the disassembly or unthreading of an upper vertically oriented joint from a lower joint, such as occurs when pulling a pipe string out of a well. In FIGS. 2 and 6, a pair of joints of drill pipe are connected end to end including a lower joint 11 and an upper joint 12. The lower joint 11 provides a box end portion 13. The upper joint 12 provides a pin end portion 14. Each of the joints 11, 12 provides a longitudinally extending, typically cylindrically shaped open ended flow bore 15, 16 respectively.
Each of the joints 11, 12 provides a wall 17, 18 respectively. In FIG. 1, a rotation of the upper joint 12 with respect to the lower joint 11 in the direction of arrow 19 enables the threads at the box and pin end portions 13, 14 to be disassembled or "destabbed" so that the joint 12 can be separated from the joint 11 in the direction of arrow 20.
In FIGS. 1-5, destabbing apparatus 10 is the form of a cylindrically shaped sleeve that includes clamp sections 21, 22 connected together with upper and lower hinges 23. Handles 24, 25 enable a user to grip the respective clamp sections 21, 22 during assembly and during disassembly of the apparatus 10 to a pair of connected joints 11, 12.
A pair of windows 26, 27 are provided respectively upon clamp sections 21, 22 as shown in FIGS. 1, 2, 3 and 6. The windows 26, 27 enable a user to place the apparatus 10 in the correct position upon a pair of assembled joints 11, 12. Preferably, the respective lower end portions 45, 46 of the windows 26, 27 are placed immediately below the upper transverse surface 47 of the lower joint 11, a distance indicated by arrow 48 as shown in FIG. 6. In this fashion, the user ensures that the apparatus 10 will be clamped to the upper end of the lower joint 11.
Because the upper end portion of the clamped sections 21, 22 are not provided with a clamp mechanism (such as the mechanism 40 at the bottom of the apparatus 10), only the bottom part of the apparatus 10 is tightly clamped to the lower joint 11. This construction enables the upper joint 12 to rotate freely with respect to the clamp sections 21, 22 during destabbing. Each of the clamp sections 21, 22 provides and upper annular edge 28 and a lower annular edge 29. The windows 26, 27 are space downwardly from the upper annular edge 28 and upwardly from the lower annular edge 29 as shown in FIG. 3.
Clamp mechanism 40 is shown more particularly in FIGS. 3-4 and 6-8. Clamp mechanism 40 is mounted at weldment 42 to clamp section 21. The weldment 42 carries a square block like body 39 with a central longitudinal bore 43 through which threaded fastener 37 passes. Threaded fastener 37 attaches at hinge 36 to link 32. The opposite end of threaded member 37 carries washer 41 and nut 43.
Spring 38 is positioned in between body 39 and washer 41 as shown in FIG. 4. Handle 33 is pivotally attached at pivot 34 to link 32. Cam 35 at one end of handle 33 is provided for engaging the recess 31 of catch 30. In order to close clamp sections 21, 22, a user holds knob 47 of handle 33 and manipulates the handle 33 until cam roller 49 engages the recess 31. The user then rotates the handle 33 in the direction of arrow 44 in FIGS. 4 and 8.
Cam roller 49 engages recess 31 of catch 30 that is welded to clamp section 22. Continued rotation of handle 33 in the direction of arrow 44 similarly rotates cam roller 49 in the direction of arrow 50. Cam links 51, 52 nest in between links 32 as shown in FIGS. 4, 6-7 as closure is completed.
Tension in spring 38 can be varied by tightening or loosening nut 37 on threaded fastener 37 to vary the distance between washer 41 and block 39. When handle 33 is rotated to the fully closed position of FIG. 4, threaded fastener 37 moves relative to bore 43 so that spring 38 can be compressed to load the connection of cam roller 49 to catch 30.
The inside surfaces of clamp sections 21, 22 are curved to conform to the outer surfaces of pipe sections 11, 12. However, the inside surfaces of the clamp sections 21, 22 can be slightly cut away above a horizontal line 53 that is also represented by transverse face 47 of lower joint 11 (see FIG. 6).
Such a cut-away surface could be a few, for example only a few tenths of a millimeter, allowing upper joint 12 to rotate a little more freely relative to lower joint 11 during destabbing. However, it has been found that the inside surfaces 54, 55 of respective clamp sections 21, 22 can define a cylinder with uniform transverse cross section since clamp mechanism 40 tightly grips lower section 11 during destabbing.
The following table lists the parts numbers and parts descriptions as used herein and in the drawings attached hereto.
______________________________________PARTS LISTPart Number Description______________________________________10 destabbing apparatus11 joint12 joint13 box end14 pin end15 flow bore16 flow bore17 wall18 wall19 arrow20 arrow21 clamp section22 clamp section23 hinge24 handle25 handle26 window27 window28 upper edge29 lower edge30 catch31 recess32 link33 handle34 pivot35 cam36 pivot37 threaded member38 spring39 body40 clamp mechanism41 washer42 weldment43 nut44 arrow45 lower end portion46 lower end portion47 knob48 arrow49 cam roller50 arrow51 cam link52 cam link53 line54 inside surface55 inside surface______________________________________
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | A method and apparatus for destabbing (disassembling) two vertically oriented drill pipe joint sections provides a two part clamp arrangement that holds the assembled joint at their interface. A lower end of the clamp arrangement is tightly clamped to the lower joint so that the upper joint rotates when the two joint are gripped with power tongs or like pipe handling devices and unthreaded or "destabbed". | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of smoothing the surface of a flexible magnetic recording medium. This invention particularly relates to a method of smoothing the surface of a flexible magnetic recording medium wherein the flexible magnetic recording medium is passed through and pressed between at least one set of two rolls at least one of which is a metal roll, thereby to smooth the magnetic surface of the medium.
2. Description of the Prior Art
As techniques for smoothing the surface of a magnetic recording medium, the following methods have heretofore been known widely:
(1) A method wherein the dispersant and the dispersing method used at the step of preparing a magnetic coating solution are improved to form a magnetic layer having a relatively smooth surface at the step immediately after the coating.
(2) A method wherein magnetic layers of recording media after coating and drying are contacted with each other and moved at high speeds with respect to each other to rub, grind and smooth the surfaces of the magnetic layers.
(3) A method wherein the magnetic layer surface is rubbed and ground with fur of animals, plastics, metals, ceramics, or the like.
(4) A method wherein the magnetic layer is smoothed by use of press rolls which are called the supercalender rolls.
However, the conventional methods described above present the problems as described below. Namely, in the method (1), the electromagnetic transducing characteristics, particularly the sensitivity and the signal-to-noise ratio obtained are not satisfactory. In the method (2), the drop out due to chipping of the magnetic layers caused by the grinding is so high that the method cannot be put into practice. In the method (3), it is impossible to conduct the surface smoothing required for a high-density recording medium. In the method (4), surface smoothing is conducted by passing a recording medium several times between a metal roll and a plastic roll. In this method, since the nip pressure of the supercalender rolls is high, large loads are exerted on the rolls and roll noise occurs when the rolls cannot withstand high pressures. Further, the middle portions of the rolls are thermally expanded due to heat generated by the rolls when the rolls are rotated in the pressed condition and/or due to heat for raising the roll temperature to a value within the range of 40° to 80° C. for the purpose of improving the smoothing effect. In this case, the pressing force of the rolls becomes uneven and, therefore, the thickness and/or smoothness of the magnetic recording medium obtained becomes uneven. In the case of a resilient roll, the hardness of the roll becomes uneven or the roll is cracked when the condition as described above continues for long periods.
In the cases of tapes wherein only one tape side is used for recording, for example, video tapes, audio tapes, and computer tapes, the purpose of smoothing the magnetic layer surface can be accomplished by conducting calendering with the magnetic layer surface contacting the surface of the metal roll of the aforesaid supercalender rolls. Therefore, supercalenders, including various improved types, are widely used.
However, since the supercalendering method has various drawbacks as described above, it is necessary to frequently replace the resilient roll or polish the roll surfaces. Thus, the method is troublesome in practical use. This method also has a drawback in that the pressure is too high (the linear pressure is within the range of 200 to 400 kg/cm) and that the roll itself must be heated (to a temperature of up to 80° C.). As magnetic tapes with higher recording density and higher performance come to be required, it is desirable to increase the temperature in smoothing above the working temperature of the conventional supercalender (in order to further smooth the magnetic surface). However, the smoothing temperature cannot be increased as desired for reasons of the conventional apparatus.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a smoothing method wherein the heating temperature for smoothing can be raised easily.
Another object of the present invention is to provide a smoothing method wherein a magnetic recording medium can be smoothed at a relatively low pressure.
The smoothing method in accordance with the present invention comprises conducting the heating necessary for smoothing by a high-frequency heating system wherein a binder (dielectric material) contained in the magnetic layer of a recording medium is heated and softened through the action of a high frequency on the molecules of the binder, and simultaneously pressing the recording medium, thereby smoothing the surface of the magnetic layer. In the present invention, since the heat is generated by the molecules of the dielectric binder, it is possible to raise the temperature more easily than by the external heating system used in the conventional calendering wherein metal rolls are heated electrically, with hot water or by dielectric heating and the magnetic layer surface of a medium is heated by the rolls. Further, since heat is generated within the magnetic layer itself, it is unnecessary to heat the rolls. (To the contrary, it will be necessary to cool the rolls by passing a refrigerant through them.)
In the present invention, since the heating temperature can be controlled as desired, it is possible to decrease the pressing force of the rolls when the recording medium is passed between them. As a result, the life of the metal roll and the resilient roll becomes long. Further, since the rolls need not be heated, the life of the rolls is further prolonged.
In the conventional supercalender, three to ten pairs of pressing and heating rolls are used, and the only way to accomplish the purpose of smoothing the surface of a magnetic layer is by continuously passing the medium between these pairs of rolls. However, in the present invention, it is sufficient to use, for example, only one or two pairs or rolls. Therefore, the apparatus for carrying out the method in accordance with the present invention is inexpensive and easy to operate and maintain.
The present invention will hereinbelow be described in further detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 are schematic views showing various embodiments of the smoothing apparatus for carrying out the smoothing method in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Recently, flexible magnetic recording media are formed by applying a mixture of a magnetic material and a binder to a plastic film (substrate), and drying the mixture to form a magnetic layer. As the magnetic material, a ferromagnetic material such as γ-Fe 2 O 3 , Fe 3 O 4 , Co-doped γ-Fe 2 O 3 , Co-doped Fe 3 O 4 , or CrO 2 is used. As the binder, for example, a vinyl chloride-vinyl acetate copolymer, a vinyl chloride-acrylonitrile copolymer, an acrylic ester-acrylonitrile copolymer, an acrylic ester-vinylidene chloride copolymer, other types of acrylic acid copolymers, a urethane elastomer, a nylon-silicone resin, nitrocellulose, a polyvinyl chloride, a vinylidene chloride-acrylonitrile copolymer, a polyamide resin, a polyvinyl butyral, a cellulose derivative, a styrene-butadiene copolymer, a phenol resin, an epoxy resin, a polyurethane, a urea resin, a melamine resin, a polyester resin, a chlorovinyl ether-acrylate copolymer, a methacrylate copolymer-diisocyanate blend polymer, an amino resin, various types of synthetic rubber, or the like may be used.
As the method of applying the magnetic coating solution, top reverse coating, bottom reverse coating, doctor coating, gravure coating, spray coating, or the like may be used. The substrate may, for example, be a non-magnetic polyethylene terephthalate film, a triacetyl cellulose film, a diacetyl cellulose film, a vinylidene chloride film, a polypropylene film, the Q Film (brand name of Teijin, Limited, in Japan) containing polyethylene naphthalate as the main ingredient, or the like. In general, the polyethylene terephthalate film is used most widely. The thickness of the substrate is, in general, within the range of 4μ to 150μ. The magnetic coating solution applied to the substrate is dried at a temperature of about 100° C. for several minutes. In the present invention, after the magnetic recording medium is prepared as described above, the dielectric resin used as the binder in the magnetic recording medium is heated and softened by the high-frequency dielectric heating method. Then, the magnetic recording medium is pressed and smoothed between a pair of highly planished rolls which are cooled by a refrigerant to a substantially constant temperature and which also serve as the high-frequency dielectric heating electrodes. The frequency used for the high-frequency dielectric heating is within the range of several kilohertz to several thousands of megahertz, and the most preferable frequency range is from several megahertz to several hundreds of megahertz.
As described below, the smoothing method in accordance with the present invention using high-frequency heating has various advantages over the external heating method used in the conventional supercalender wherein metal rolls are heated electrically, with hot water or by dielectric heating and a medium is heated by the rolls:
(1) Heating is conducted uniformly since the heat is generated by the molecules within the dielectric binder.
(2) Since heat is internally generated in the medium, temperature unevenness in the thickness direction of the medium does not occur as it does in the case of the conventional external heating as described above. (In the conventional external heating, the surface of the medium becomes hot, but the inside of the medium does not.)
(3) The temperature of the medium rises quickly, and the temperature rise speed can be controlled as desired.
(4) When the material to be heated is a composite material comprising materials exhibiting dielectric constants or power factors different from each other, it is possible to selectively heat the material. In the magnetic recording medium, the polyethylene terephthalate film used as the substrate is not heated, and only the magnetic layer can be heated.
(5) The apparatus is inexpensive compared with the other external heating systems.
The material that can be heated by the dielectric heating at a frequency within the aforesaid range is mainly the binder used in the magnetic layer. As is well known, the dielectric constant and the dielectric power factor of a dielectric substance are the important factors in heating, and the amount of heat generated (P) can be represented by the formula
P=k×f×ε×E.sup.2 ×tan δ×10.sup.-12 (W/cm.sup.3)
wherein k designates the coefficient, f denotes the frequency applied, ε designates the dielectric constant, E denotes the intensity of electric field, and tan δ denotes the dielectric power factor.
Among the aforesaid binder materials used in the magnetic layer, vinyl chloride, vinyl chloride-vinyl acetate, vinylidene chloride, urethane and polyamide compounds are readily heated by dielectric heating. Particularly, vinyl chloride, vinyl chloride-vinyl acetate and vinylidene chloride compounds are very readily heated by dielectric heating.
FIGS. 1 to 3 show various embodiments of the apparatus for carrying out the smoothing method in accordance with the present invention. In FIG. 1, a flexible web-like magnetic recording medium 1 is heated and pressed between a pair of metal rolls 2, 2. The metal rolls 2, 2 serve also as high-frequency dielectric heating electrodes to which a high frequency is applied from a high-frequency generator 4. The heating temperature is controlled by a temperature regulator 5. After smoothing, the web-like magnetic recording medium 1 is wound up around a web wind-up roll 6.
In FIG. 2, pressing and heating are conducted by use of rolls 3, 3 which comprise metal rolls with plastic films 7 laid on the surfaces thereof.
In FIG. 3, two pairs of rolls 3, 3 as shown in FIG. 2 are used to press and heat the web-like magnetic recording medium 1.
The press rolls serving also as high-frequency dielectric heating electrodes should be highly planished on the surfaces and involve no eccentricity as in the case of the conventional supercalender rolls. The metal rolls may be constituted by metal rolls with plastic films, flat plates, or the like provided on the surfaces thereof. The plastic films, film plates, or the like laid on the metal rolls may be made of a silicone resin, a glass fiber-containing polyester resin, an FRP, ethylene tetrafluoride (Teflon), a varnish-containing cotton cloth, a phenol resin (Bakelite), asbestos, cellophane, mica, glass, or the like.
TABLE 1______________________________________Composition Parts by weight______________________________________γ-Fe.sub.2 O.sub.3 (0.4 × 0.07 × 0.07μ) 300Vinyl chloride-vinyl acetate resin 50Urethane resin 30Plasticizer (Triphenylphosphate) 5MEK:toluene (4:6) 900______________________________________
A coating solution was prepared by dispersing the composition as shown in Table 1 for 48 hours in a ball mill. Then, the coating solution was applied to a 20μ-thick polyethylene terephthalate film so as to obtain a dry coating thickness of 5μ. In this manner, a 1000 m bulk roll was obtained.
Half of the obtained bulk roll was processed in a conventional supercalender (with the magnetic surface facing the metal roll side) (metal roll temperature: 80° C., linear pressure: 300 kg/cm, web speed: 50 m/min). The remaining half of the bulk roll was processed by the smoothing apparatus in accordance with the present invention. Heating was conducted at an output of 4 kW and a frequency of 45 MHz. Pressing was conducted by use of a pair of the same planished metal rolls as the metal rolls used in the aforesaid supercalender. The temperature of both rolls was adjusted to 33°±2° C. Thus, a pair of rolls were used, the linear pressure was 80 kg/cm, and the web speed was 50 m/min.
The glossiness under 45° exposure was measured according to JIS Z 8741, and the surface smoothness of the samples was compared. (The 45° glossiness when black glass having a refractive index of 1.56 was used was taken to be 98.3 as the reference glossiness.) It was found that the glossiness of the samples processed according to the conventional supercalendering was 71, and the glossiness of the samples processed in accordance with the present invention was 95. | The surface of a flexible magnetic recording medium is continuously smoothed between at least one set of two rolls at least one of which is a metal roll. The rolls serve as electrodes of a high-frequency dielectric heater. A refrigerant is fed to the electrodes, and a high frequency is applied to the electrodes while the recording medium is passed and pressed between the rolls. | 8 |
FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to an image heating device used by an image forming apparatus such as a copying machine, a laser beam printer, etc., which uses an electrophotographic image formation process, an electrostatic recording process, or the like image formation process.
[0002] There are various image heating devices, for example, a fixing device for heating an unfixed toner image on a sheet of recording medium in order to fix the toner image to the sheet, and a glossing device for heating a fixed image on a sheet of recording medium in order to increase the image in gloss.
[0003] An image heating device of the so-called heat roller type, and an image heating device of the so-called film heating type, have long been used as a fixing device by an image forming apparatus which uses an electrophotographic image forming method, an electrostatic image recording method, or the like.
[0004] Further, there has been proposed to replace a pressure roller used by a conventional fixing device of the so-called heat roller type, with a pressure pad, in order to reduce a conventional fixing device of the so-called heat roller type in size, for special efficiency. A pressure pad is a stationary member for applying pressure to a sheet of recording medium while the sheet is conveyed between itself and a heat roller (so-called pad type).
[0005] Unlike a fixing device of the so-called heat roller type and the like, a fixing device which uses a stationary pad to apply pressure to a sheet of recording medium and an unfixed toner image thereon does not require that a heat source or the like is placed within a fixation roller. Therefore, it makes it possible to reduce a heat roller in diameter to reduce the heat roller in thermal capacity. Further, a pressure pad is simpler in structure than other pressure applying members. Therefore, not only can it simplify an image heating device (fixing device) in overall structure, but also, reduce an image heating device in size and cost. Therefore, it is reasonable to say that an image fixing method which uses a pressure application pad is suitable to reduce a fixing device in warm up time and energy consumption.
[0006] One of the structures for a fixing device which uses a pressure application pad as a pressure applying member is listed in Japanese Laid-open Patent Application 2008-20789. According to this application, a pressure pad is molded of an adiabatic substance, such as resin, in a single-piece, in order to ensure that even after a pressure pad is frictionally worn through usage, it does not reduce a fixing device in recording medium conveyance performance. However, a pressure pad, such as the one disclosed in the application, suffers from the following problem. If a pressure pad is formed of an adiabatic substance, in particular, a resinous substance, the nip of a fixing device is likely to fail to properly nip a sheet of recording medium, causing thereby a sheet of recording medium to often stop before the nip (nipping error). Thus, the inventors of the present invention earnestly studied this phenomenon, and discovered that one of the factors related to “nipping error” is that the surface of a pressure pad becomes electrically charged, whereby a sheet of recording medium is adhered to the pressure pad by the electrostatic force generated by the electrical charge of the pressure pad.
[0007] More specifically, the surface of a pressure pad is electrically charged by the friction between the surface of the pressure pad and the peripheral surface of the fixation roller which is a rotational heating member. As a result, an electrostatic force which adheres a sheet of recording medium to the surface of the pressure pad develops. If the sum of the amount of this electrostatic force and the amount of the friction between the pressure pad and a sheet of recording medium exceeds the amount of force which works in the direction to push the sheet of recording medium into the fixing device (fixation nip), the “nipping error” is likely to occur, in particular, in a case where the distance between the transfer station and fixing device is large, and therefore, it is easier for a sheet of recording medium to deform before it enters the fixing device (fixation nip), in a case where the transfer station is low in internal pressure, being therefore weaker in recording medium conveyance force.
[0008] The following has been known: Until a certain length of time elapses after a fixing device is started, the amount of electrical charge of a pressure pad does not become substantial, and therefore, “nipping error” does not occur. However, as the fixing device increases in the length of time it is being continuously used for a certain length of time, its pressure pad increases in potential level, which in turn increases the amount of electrostatic force between the pressure pad and a sheet of recording medium on the pressure pad. Consequently, the fixing device increases in the probability with which it suffers from “nipping error”.
[0009] As for a means for improving a fixing device of the so-called pressure pad type in terms of “nipping error”, it is possible to plate the pressure pad with a metallic substance, or use a metallic substance as the material for the portion of the pressure pad, which contacts a heating member. However, if a metallic substance is used as the material for the portion of the pressure pad of a fixing device, which contacts a heating member, the peripheral surface of the heating member of the fixing device is frictionally worn at a higher rate. As the peripheral surface of the heating member wears, the heating member reduces in recording medium conveyance force, that is, the amount of force it can apply to a sheet of recording medium to convey the sheet. Therefore, plating the pressure pad of a fixing device with a metallic substance reduces the fixing device in recording medium conveyance force. Further, a metallic substance is inferior in its ability to allow toner particles, paper dust, and the like to part from itself. Therefore, as a substantial number of sheets of recording medium are conveyed through a fixing device of the pressure pad type, toner particles, paper dust, and the like are likely to cumulatively adhere to the downstream side of the recording medium backing surface of the pressure pad, relative to the fixation nip, in terms of the recoding medium conveyance direction, and contaminate a sheet of recording medium.
SUMMARY OF THE INVENTION
[0010] Thus, the primary object of the present invention is to provide an image heating device which is unlikely to fail to properly nip a sheet of recording medium, being therefore capable of reliably conveying a sheet of recording medium, and is unlikely to contaminate a sheet of recording medium.
[0011] According to an aspect of the present invention, there is provided an image heating device comprising a heating rotatable member; and a pressing pad contacted to said heating rotatable member and forming a nip with said heating rotatable member to nip and feed a recording material, said pressing member being provided with an electroconductive material dispersed resin material layer contacting said heating rotatable member.
[0012] According to another aspect of the present invention, there is provided an image heating device comprising a heating rotatable member; and a pressing pad contacted to said heating rotatable member and forming a nip with said heating rotatable member to nip and feed a recording material, said pressing member being provided with an electroconductive material dispersed resin material layer contacting said heating rotatable member in a region upstream of the nip with respect to a feeding direction of the recording material.
[0013] These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic sectional view of the fixing apparatus in the first preferred embodiment of the present invention, at a plane perpendicular to the axial line of the heating member.
[0015] FIG. 2 is a schematic drawing for describing the method for measuring the amount of the electrical resistance of the pressure pad.
[0016] FIG. 3 is a graph which shows the relationship between the potential level of the pressure pad and the amount of electrostatic force which attracts a sheet of recording medium to the pressure pad.
[0017] FIG. 4 is a schematic sectional view of the image forming apparatus having an image heating device as a fixing device, at a plane perpendicular to the recording medium conveyance direction. It shows the general structure of the apparatus.
[0018] FIG. 5 is a schematic sectional view of the combination of the transfer station and fixing device. It is for describing the mechanism which causes the transfer station to suffer from unsatisfactory image transfer.
[0019] FIG. 6 is an equivalent circuit of the combination of the transfer station and fixing device.
[0020] FIG. 7 is a schematic sectional view of the pressure pad in the seventh preferred embodiment of the present invention, at a plane perpendicular to the lengthwise direction of the pressure pad.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Hereinafter, the preferred embodiments of the present invention are described with reference to the appended drawings, in which the corresponding components, their portions, etc., of the image forming apparatuses are given the same referential code.
Embodiment 1
(Image Forming Apparatus)
[0022] FIG. 4 is a schematic sectional view of a typical image forming apparatus having an image heating device in accordance with the present invention. It shows the general structure of the apparatus. This image forming apparatus is an electrophotographic laser beam printer.
[0023] The printer 101 in this embodiment receives the information of the image to be formed, from an apparatus (unshown), such as a host computer, which is outside the main assembly 101 a of the printer. The printer 101 carries out one of the known electrophotographic image formation processes to record an image on a sheet P of recording medium, based on the received information of the image to be formed.
[0024] The printer 101 employs a process cartridge 104 . The process cartridge 104 has: an electrophotographic photosensitive member 102 , as an image bearing member, which is in the form of a drum; a primary charging system 108 ; and a developing device 103 . The printer 101 has also a laser scanner unit 105 . The laser scanner unit 105 forms on the peripheral surface of the photosensitive drum 102 , an electrostatic latent image which reflects the information of the image to be formed. As described above, the information of the image to be formed, which hereafter will be referred to simply as “image information” is provided by the aforementioned image information providing apparatus. Further, the printer 101 has a transfer member 106 and a fixing device 107 . The transfer member 106 is for transferring an image onto the sheet P of recording medium. It is in the form of a roller, and is rotatable. The fixing device 107 is a thermal fixing device which is for fixing an unfixed image on the sheet P of recording medium to the sheet P by the application of heat and pressure to the sheet P and the image thereon.
[0025] Next, the image formation sequence carried out by the printer 101 is described. As the printer 101 receives a print signal, the photosensitive drum 102 begins to be rotated in the clockwise direction indicated by an arrow mark K 1 at a preset peripheral velocity. At the same time as the photosensitive drum 102 begins to be rotated, the peripheral surface of the photosensitive drum 102 begins to be uniformly charged to preset polarity and potential level by the primary charging system 108 to which a preset bias is being applied. In this embodiment, the polarity to which the peripheral surface of the photosensitive drum 102 is charged is negative. Thus, an electrostatic latent image is developed in reverse. That is, after the uniformly charged area of the peripheral surface of the photosensitive drum 102 is exposed by the laser scanner unit 105 , the developer (toner) is adhered to the exposed points of the peripheral surface of the peripheral surface of the photosensitive drum 102 .
[0026] Next, the uniformly charged area of the peripheral surface of the photosensitive drum 102 is scanned (exposed) by the scanner unit 105 according to the image information received from the image information providing apparatus. As a given point of the uniformly charged area of the peripheral surface of the photosensitive drum 102 is exposed, it is reduced in potential, becoming therefore positive relative to an unexposed point. As a result, an electrophotographic latent image, which reflects the image information, is effected on the peripheral surface of the photosensitive drum 102 . Meanwhile, the developer in the developing device 103 is negatively charged. The negatively charged developer is adhered to the exposed points of the uniformly charged area of the peripheral surface of the photosensitive drum 102 , which are positive relative to the unexposed points of the uniformly charged area of the peripheral surfaces of the photosensitive drum 102 ; the exposed points are developed. Consequently, the electrostatic latent image on the peripheral surface of the photosensitive drum 102 is developed into a visible image; a visible image is formed of the developer on the peripheral surface of the photosensitive drum 102 .
[0027] Meanwhile, a sheet conveyance roller 112 is driven with a preset timing, whereby a sheet P of recording medium is fed into the main assembly 101 a from a sheet feeder cassette 111 while being separated from the rest of the sheets P in the cassette 111 . The sheet feeder cassette 111 is capable of storing in layers multiple sheets P of recording medium. It is removably mountable in the main assembly 101 a of the printer 101 . After being fed into the main assembly 101 a from the sheet feeder cassette 111 , the sheet P of recording medium is sent to a pair of registration rollers 113 , and is temporarily held there. Then, it is released with a preset timing by the pair of registration rollers 113 to be conveyed to the transfer nip, that is, the nip formed between the peripheral surface of the photosensitive drum 102 and image transferring member 106 . Then, it is conveyed through the transfer nip while remaining pinched between the photosensitive drum 102 and image transferring member 106 . It is while the sheet P is conveyed through the transfer nip that the toner image on the photosensitive drum 102 is transferred onto the sheet P by the image transferring member 106 as if it is peeled away from the photosensitive drum 102 .
[0028] After the transfer of the toner image onto the sheet P of recording medium, the toner image (unfixed) is thermally fixed to the sheet P by the fixing device 107 . Then, the sheet P is conveyed further by a pair of rollers 114 which are rotatably supported on the downstream side of the fixing device 107 in terms of the recording medium conveyance direction, and then, is discharged from the apparatus main assembly 101 a by a pair of discharge rollers 115 , into a delivery tray 116 in such a manner that it is layered on the sheets P in the tray 116 . The delivery tray 116 is an integral part of the top wall of the main assembly 101 a of the printer 101 . The discharging of the sheet P into the delivery tray 116 concludes the image formation sequence.
(Process Cartridge)
[0029] Opening a cover 109 , shown in FIG. 4 , makes it possible for the process cartridge 104 to be mounted into, or removed from, the main assembly 101 a of the printer 101 .
(Image Heating Device)
[0030] Next, referring to FIG. 1 , the structure of the fixing device 107 which is an image heating device in accordance with the present invention is described. The fixing device 107 is for thermally fixing an unfixed toner image formed by an ordinary electrophotographic image forming method. More specifically, the sheet P of recording medium, on which an unfixed toner image is present, is conveyed through the fixing device 107 by an unshown recording medium conveying means, from the right-hand side of the fixing device 107 (with reference to FIG. 1 ). As the sheet P is conveyed through the fixing device 107 , the unfixed toner image is thermally fixed to the sheet P. Designated by a referential numeral 1 is a fixation roller as a rotatable heating member which heats the sheet P and the toner image thereon while conveying the sheet P. Designated by a referential numeral 2 is a heater as a means for externally heating the fixation roller 1 of the fixing device 107 . Designated by a referential numeral 3 is a heater holder as a member for holding the heater 2 . Designated by a referential numeral 5 is a pressure pad as a stationary pressure applying member, which opposes the fixation roller 1 .
[0031] The fixation roller 1 comprises a metallic core, an adiabatic elastic layer 12 , and at least one thermally conductive layer 13 . The material for the metallic core 11 is aluminum, iron, SUS (stainless steel) SUM (free-cutting steel), or the like. The adiabatic elastic layer 12 is formed of a substance which is low in thermal conductivity. It covers the entirety of the peripheral surface of the metallic core 11 . The thermally conductive layer 13 covers the peripheral surface of the elastic layer 12 .
[0032] The material for the adiabatic elastic layer 12 is balloon rubber, sponge rubber, or the like, for example. Balloon rubber is a mixture of silicone rubber and hollow filler (such as micro balloons). Sponge rubber is formed by causing silicon rubber to foam with the use of a mixture of water and foaming agent. Further, the material for the adiabatic elastic layer 12 may be a solid rubber which is low in thermal conductivity.
[0033] More specifically, as the material for the thermally conductive layer 13 , a highly thermally conductive substance made by mixing highly thermally conductive filler into silicon rubber or fluorinated rubber is used. Using the above-described substance as the material for the thermally conductive layer 13 makes it possible to provide a fixation roller which is high in thermal conductivity and can generate friction which is necessary to convey the sheet P of recording medium through a fixing device (fixation nip). In this embodiment, the metallic core 11 is 6 mm in diameter. The adiabatic elastic layer formed of the balloon rubber (rubber which contains micro-balloons), on the peripheral surface of the metallic core 11 , is 3 mm in thickness. The layer of highly thermally conductive silicone rubber formed on the peripheral surface of the balloon silicon rubber layer 12 , of the silicon rubber made by dispersing aluminum particles, as thermally conductive filler, in the silicon rubber, is 150 μm in thickness.
[0034] The heater 2 has a substrate 21 and a layer 22 of heat generating resistor. The substrate 21 is long and narrow, and its lengthwise direction is perpendicular to the recording medium conveyance direction. It is formed of dielectric ceramic (such as alumina and aluminum nitrate), or heat resistant resin (such as polyimide, PPS, and liquid polymer). The layer 22 of heat generating resistor is formed of an electrically conductive substance, such as Ag/Pd (silver-palladium), RuO 2 , Ta 2 N, on the surface of the substrate 21 , with a method such as screen printing. It also is in the form of a piece of wire, or long and narrow strip. It extends in the lengthwise direction of the substrate 21 . Further, the heater 2 has a dielectric protective layer 23 which covers the entirety of the surface of the layer 22 of heat generating resistor to protect and insulate the layer 22 . The dielectric protective layer 23 is formed of a dielectric substance such as glass, polyimide, or the like.
[0035] Further, the heater 2 may be provided with a parting layer (unshown), as a surface layer, which covers the entirety of the dielectric protective layer 23 , not only to reduce the friction between the heater 2 and the peripheral surface of the fixation roller 1 , but also, to prevent the unfixed toner on the sheet P of recording medium, from adhering to the heater 2 .
[0036] In the case of the heater 2 in this embodiment, the substrate 21 is formed of alumina, and the heat generating resistor layer 22 is formed of Ag/Pd. The dielectric protectively layer 23 is formed by coating the surface of the heat generating resistor layer 22 with glass. The heater 2 is held to the heater holder 3 by the substrate 21 in such an attitude that the protective layer 23 of the heater 2 faces the peripheral surface of the fixation roller 1 . The heater holder 3 is made of a heat resistant resin such as liquid polymer, PPS, PEEK, or the like. Its lengthwise ends are in engagement with a stay 4 held to the fixing device frame.
[0037] Further, the fixing device 107 has a pair of compression springs (unshown), as pressure applying means which apply pressure to the lengthwise end of the stay 4 . Thus, the heater holder 3 is kept pressed toward the fixation roller 1 . The pressure applied to the stay 4 by the pair of compression springs has to be uniformly transmitted to the heat holder 3 in terms of the lengthwise direction of the heat holder 3 . Thus, a rigid substance such as iron, stainless steel, SUM, zinc-coated steel plate, etc., is used as the material for the stay 4 . Further, the stay 4 is made U-shaped in cross section, or the like, to further increase it in rigidity.
[0038] Since the fixing device 107 is structured as described above, the protective layer 23 of the heater 2 is placed and kept in contact with the peripheral surface of the fixation roller 1 , forming thereby a heating nip between the heater 2 and fixation roller 1 . Further, since the heater holder 3 is formed of the above descried material and is structured as described above, the heating nip remains uniform in width. In this embodiment, liquid polymer is used as the material for the heater holder 3 , whereas the material for the stay 4 is zinc-coated steel plate.
[0039] The pressure pad 5 , which is a stationary pressure applying member, is made up of a substrate 51 and a recording medium backing layer 52 . The substrate 51 is long and narrow, and its lengthwise direction is perpendicular to the recording medium conveyance direction. The recording medium backing layer 52 is on the substrate 51 . As for the material for the substrate 51 , it may be any substance as long as it is suitable for the formation and positioning of the substrate 51 . However, in order to ensure that as the pressure pad 5 is pressed upon the peripheral surface of the fixation roller 1 , it forms the heating nip which is uniform in width and internal pressure, the material for the substrate 51 is desired to be more or less rigid. Further, it is required to withstand the high level of temperature to which it is subjected when the recording medium backing layer 52 is formed through a process which includes coating and sintering, as will be described later. Therefore, it is desired that a metallic substance such as iron, stainless steel, SUM, zinc-coated steel plate, or the like is used as the material for the substrate 51 .
[0040] In this embodiment, the substrate 51 of the pressure pad 5 is made of a piece of zinc-coated steel plate, and is bent in the shape shown in FIG. 1 . The pressure pad 5 is under a total pressure of 5 kg applied by the aforementioned pair of compression springs.
[0041] The material for the recording medium backing layer 52 is desired to be low in frictional resistance so that it does not impede the conveyance of the sheet P of recording medium by the friction between the recording medium backing layer 52 and the sheet P of recording medium. Further, from the standpoint of preventing the problem that the contaminants such as the toner particles, and the like, having transferred from the sheet P of recording medium onto the fixation roller 1 , adhere to the recording medium backing layer 52 , the material for the recording medium backing layer 52 is desired to have parting properties. Thus, it is desired that fluorinated resin such as PTFE, FEP, PFA, etc., PEEK (poly ether-ether ketone), PAI (polyamideimide), PI (polyimide), or the like is used as the material for the recording medium backing layer 52 . As for the method for forming the recording medium backing layer 52 , the recording medium backing layer 52 may be formed by spray-coating the surface of the substrate 51 with the material for the recording medium backing layer 52 , or dipping the substrate 51 into the material for the recording medium backing layer 52 . Further, it may be formed by making a piece of thin sheet of the material for the recording medium backing layer 52 , the thickness of which is in a range of several micrometers—several hundreds of micrometers, and solidly attaching the piece to the substrate 51 . Further, the recording medium backing layer 52 is made electrically conductive to prevent the recording medium backing layer 52 from being electrically charged by the friction which occurs between the recording medium backing layer 52 and the peripheral surface of the fixation roller 1 as the fixation roller 1 is rotated.
(Method for Making Recording Medium Backing Layer 51 Electrically Conductive)
[0042] The recording medium backing layer 52 is made electrically conductive by dispersing electrically conductive substance (carbon, for example) into the resinous material for the recording medium backing layer 52 , with the use of one of the known manufacturing methods, which uses a mixing roller, a pressurized kneader, an extruder, a three roll mill, a homogenizer, a ball mill, a piece mill, or the like, for example. Further, various additives, such as plasticizer, coloring agent, charge inhibitor, aging inhibitor, oxidization inhibitor, reinforcement filler, reaction accelerator, etc., may be added to the material for the recording medium backing layer 52 as necessary.
[0043] As the particles for providing the recording medium backing layer 52 with electrical conductivity, minute particles of the following substances can be listed: metallic substance such as aluminum, copper, nickel, and silver; and oxides of electrically conductive metals, such as antimony oxide, indium oxide, tin oxide, titanium oxide, zinc oxide, molybdenum oxide, and potassium titanate; various carbon fiber; carbon black, such as furnace black, lamp black, thermal black, acetylene black, and channel black; and metallic fiber.
[0044] Among those substances listed above, carbon black, in particular, electrically conductive amorphous carbon black, is a preferable material for providing the recording medium backing layer 52 with electrical conductivity. The reasons why the electrically conductive amorphous carbon black is preferable among those substances listed above are as follows: First, it is excellent in electrical conductivity, being therefore capable of providing a high polymer with electrical conductivity by being dispersed in the high polymer, and further, the mount of electrical conductivity which it can provide can be somewhat controlled by controlling the amount by which it is dispersed in the high polymer. Secondly, it has a thixotropic effect. Therefore, it remains uniformly dispersed as it is dispersed in a paint made up of high polymer, and also, when and after the paint is coated on the substrate 51 .
[0045] The proper amount by which carbon black is to be dispersed into the resinous substance as the material for the recording medium backing layer 52 varies depending on the particle diameter of carbon black.
[0046] However, it is desired to be in a range of no less than one part of carbon black, and no more than 100 parts, per 100 parts of the resinous substance (bonding resin) as the material for the recording medium backing layer 52 . It is within this range that the resultant recording medium backing layer 52 is roughly at a preset value in terms of electrical resistance, and also that it is not unsatisfactorily low in mechanical strength (resistant to frictional wear).
[0047] In this embodiment, the recording medium backing layer 52 , which is 50 μm in thickness, is formed on the substrate 51 by spraying the material made by dispersing carbon into PFA (copolymer of polytetrafluoroethylene and perfluoroalkylvinylether), onto the surface of the substrate 51 , and sintering the material on the substrate 51 .
[0048] FIG. 2 shows the method for measuring the electrical resistance of the pressure pad 5 . As will be evident from FIG. 2 , first, a roller 6 for measuring the amount of electrical resistance of the pressure pad 5 is stationarily placed in contact with the surface of the recording medium back layer 52 of the pressure pad 5 , and is connected to an electrical power source 9 with the presence of an ammeter 7 between the roller 6 and power source 9 . Then, 100 V-1,000 V of voltage is applied between the recording medium backing layer 52 and power source 9 . The amount of electrical resistance of the pressure pad 5 can be obtained by monitoring the amount of electrical current which flows through the ammeter 7 . The roller 6 was made by wrapping the fixation roller 1 in this embodiment with a sheet of aluminum foil. The amount R of the electrical resistance of the pressure pad 5 can be obtained from the following equation, in which I and V stand for the amount of electrical current, and the voltage:
[0000] R (Ω)= V/I.
[0049] In the case of the pressure pad 5 in this embodiment, the amount of the electrical current which flowed through the ammeter 7 when 1,000 V of voltage was applied was roughly 100 μA. Thus, the amount of electrical resistance of the pressure pad 5 is roughly 10 MΩ. Incidentally, the substrate 51 of the pressure pad 5 in this embodiment is metallic. Therefore, the amount of electrical resistance of the pressure pad 5 , which can be obtained using the above-described method is the amount of electrical resistance of the portion of the resinous layer (recording medium supporting layer) of the pressure pad 5 , which corresponds in position to the fixation nip N. The pressure pad 5 is under the total pressure of 5 kg which is from the unshown pair of compression springs. Thus, it forms the fixation nip N, which is roughly uniform in width and internal pressure in terms of the direction perpendicular to the recording medium conveyance direction. In this embodiment, the pressure pad 5 is grounded. As described above, the fixing device 107 in this embodiment has a pressure applying member 5 (pressure pad), which forms a nip between itself and the peripheral surface of the rotational heating member 1 (fixation roller 1 ) by being pressed upon the peripheral surface of the rotational heating member, and which conveys the sheet P of recording medium through the nip while keeping the sheet P between itself and rotational heating member 1 . The pressure applying member 5 is grounded. The surface of the pressure applying member 5 , which is in contact with the rotational heating member 1 , is the surface of the recording medium backing layer 52 of the pressure applying member 5 , which is formed of a resinous substance in which particles of electrically conductive substance are dispersed.
[0050] As an image forming operation is started by the image forming apparatus, the fixation roller 1 begins to be rotated. At the same time, electric power begins to be supplied to the heater 2 while being controlled by an unshown control circuit. Thus, the heater 2 increases in temperature, heating thereby the fixation roller 1 . As the temperature of the fixation roller 1 reaches a level high enough for fixation, the sheet P of recording medium on which an unfixed toner image is present is introduced into the fixation nip, and conveyed through the fixation nip while being given heat by the fixation roller 1 and kept pressed against the fixation roller 1 by the pressure pad 5 . As a result, the unfixed toner image on the sheet P becomes fixed to the surface of the sheet P.
[0051] The image heating device in this embodiment was tested in its nipping performance, using the following method. That is, the image heating device in this embodiment was set in the laser beam printer (commercial name: Laser Jet P1006: product of Hewlett Packard Co., Ltd.), which is the electrophotographic image forming apparatus, and is driven at a process speed of 107 mm/sec. The recording medium was a sheet of Business 4200 paper (commercial name: product of Xerox Co., Ltd.), which was 75 g/m 2 in basis weight. In the test, the sheets of recording medium were conveyed through the fixing device 107 at a rate of 17 sheets per minute to test the fixing device 107 in nipping performance. The test results were very satisfactory. That is, while the maximum number (150) of sheets which can be fed per sheet feeder cassette 111 were conveyed through the fixing device 107 , the fixing device 107 never failed to properly nip the sheet. Further, the amount of surface potential of the pressure pad 5 measured after the conveyance of 150 sheets was no higher than 1 kV, proving that the pressure pad 5 was hardly charged.
(First Comparative Fixing Device)
[0052] For comparison, a pressure pad 5 , the recording medium backing layer 52 of which is formed of electrically nonconductive substance, was made. This pressure pad 5 is different from the pressure pad 5 in the first embodiment in that while the recording medium backing layer 52 of the latter is made of electrically conductive PFA, that is, PFA resin in which carbon particles are dispersed, whereas the recording medium backing layer 52 of the former is made of electrically nonconductive PFA resin, that is, PFA resin which does not contain carbon particles.
[0053] The first comparative fixing device was set in a laser beam printer similar to that used to test the pressure pad 5 in the first embodiment, and was subjected to the same recording medium conveyance test as the one used to test the pressure pad 5 in the first embodiment. In the case of the first comparative fixing device, the unfixed toner images on only the first several sheets of recording medium were normally fixed. Thereafter, the problem that a sheet of recording medium fails to be properly nipped by the fixation nip of a fixing device and stops at the entrance of the nip frequently occurred. The amount of surface potential level of the pressure pad 5 of this comparative fixing device measured after the problem began was no less than 4 kV.
[0054] FIG. 3 is a graph which shows the relationship between the amount of electrical charge of the pressure pad 5 and the amount of electrostatic force which adheres a sheet of recording medium to the pressure pad 5 . It shows the effect of the changes in the amount of electrical potential of the pressure pad 5 , upon the amount of electrostatic force by which a sheet of recording medium is adhered, and kept adhered, to the pressure pad 5 . In the test, the amount of electrostatic force by which a sheet of recording medium is adhered to the pressure pad 5 at a given level of electrical potential which is forcefully applied between the pressure pad 5 and fixation roller 1 by a high voltage power source was measured. More specifically, a sheet of recording paper, which is the same as the one used to test the fixing device in the first embodiment and the first comparative fixing device, was placed on the pressure pad 5 . Then, while the potential of the pressure pad 5 is kept at a preset level, the sheet was gently pulled, and the amount force necessary to budge the sheet was measured. As will be evident from FIG. 3 , the higher the potential level of the pressure pad 5 , the greater the amount of electrostatic force which keeps the sheet of recording medium adhered to the pressure pad 5 .
[0055] In another test, a sheet of recording paper, which is the same as the one used to test the fixing device in the first embodiment and the first comparative fixing device, is also placed on the pressure pad 5 . Then, the sheet was gently pushed from one side of the sheet, with the sheet being held at the other side to prevent the sheet from moving, and the amount of force necessary to cause the sheet to begin to deform (bend) was measured while the potential of the pressure pad 5 is kept at a preset level (hereafter, this force is referred to as “buckling load”). The amount of “buckling load” was 118 gf. It is evident from this test that as the amount of electrostatic force, shown in FIG. 3 , which keeps a sheet of recording paper adhered to the pressure pad 5 , exceeds the amount of the “buckling load”, that is, as the pressure pad 5 is charged to a potential level of roughly 3,800 V or higher, the amount of the electrostatic force exceeds the amount of “buckling load”, and therefore, the fixing device fails to properly nip a sheet of recording medium.
[0056] Further, in an additional test, the amount of the above described electrostatic force and “buckling load” were measured using various sheets of ordinary paper, which are in a range of 60 g/m 2 -90 g/m 2 , instead of the sheet of Business 4200 paper (product of Xerox Co., Ltd.) which is 75 g/m 2 in basis weight and was used to test the fixing device in the first embodiment and the first comparative fixing device.
[0057] The amount of the buckling load was in a range of 85 gf-150 gf, which is different from the range of the amount of bucking load of the sheet of Business 4200 paper, whereas the amount of the electrostatic force was hardly different from when the sheet of Business 4200 was used. It is evident from the results of the above-described tests that from the standpoint of practicality, the fixation pad 5 is desired to be kept no higher in potential level than 2,000 V.
[0058] As will be evident from the description of the first preferred embodiment of the present invention given above, the present invention makes it possible to prevent the stationary pressure applying member of a fixing device from being electrically charged. Therefore, not only can the present invention prevent the problem that a fixing device fails to properly nip a sheet of recording medium, but also, the problem that a fixing device, the material for the pressure applying stationary member of which is a metallic substance, fails to properly convey a sheet of recording medium, and/or contaminates a sheet of recording medium.
Embodiments 2-4, and Second Comparative Fixing Device
[0059] The second to fourth preferred embodiments of the present invention, and the second comparative fixing device, are different in the amount of the carbon dispersed in the recording medium backing layer of their pressure pad, being therefore, different in the amount of electrical resistance of the pressure pad 5 . More concretely, in order to find the upper limit for the amount of the electrical resistance of the pressure pad 5 , four pressure pads were made, which are different in the amount of the electrically resistance. As for the method for making four pads different in the amount of electric resistance, the amount by which carbon (which is for providing pressure pad with electrical conductivity) is dispersed in the PFA resin as the material for the pressure pad is varied. The measured amounts of electrical resistance of the pressure pads in the second, third, and fourth embodiment, and the pressure pad of the second comparative fixing device, were 10 8 Ω, 10 10 Ω, 10 12 Ω, and 10 14 Ω, respectively. These pads were mounted in a fixing device similar to the one used to test the pressure pad 5 in the first embodiment, and the fixing device was mounted in an image forming apparatus similar to the one in the first embodiment.
[0060] Then, 150 sheets of recording paper were conveyed with the use of the same methods as those used to test the pressure pad in the first embodiment, while measuring the amount of the surface potential of each pad and examining whether or not the fixing device failed to properly nip the sheets. The test results were as shown in Table 1. However, the pressure pad which is 10 14 Ω in the amount of electrical resistance caused the fixing device to frequently fail to properly nip a sheet after the 50th sheet and thereafter. Thus, the value of electrical resistance of this pad shown in Table 1 is the one obtained when the 50th sheet was conveyed.
[0000]
TABLE 1
10 8 Ω
10 10 Ω
10 12 Ω
10 14 Ω
Resistance of
Embodi-
Embodi-
Embodi-
Comparative
Fixing pad
ment 2
ment 3
ment 4
Ex. 3
Surface potential
≦1000 V
≦1000 V
Aporox.
Approx.
of backing layer
2000 V
4000 V
after 1500 sheets
were processed
Improper
no
no
no
Occurred
nipping
often after
50 sheet
[0061] It is evident from the results of the above described test that the amount of electrical resistance of the pressure pad 5 is desired to be no more than 10 12 Ω. More specifically, the portion of the resin layer (recording medium backing layer) of the pressure pad 5 , which corresponds in position to the fixation nip, is desired to no more than 10 12 Ω. Further, in consideration of the nonuniformity in terms of the amount of “buckling load” among various sheets of recording medium, it is desired to be no more than 10 10 Ω.
Embodiments 5 and 6, and Third Comparative Fixing Device
[0062] In order to find the bottom limit for the amount of electrical resistance of the pressure pad 5 , it is checked whether or not a problem occurs if the pressure pad 5 is lower in the amount of electrical resistance than certain values. More specifically, a resistor which can be varied in the amount of electrical resistance was connected to each of the pressure pads 5 in the fifth and sixth embodiments of the present invention, and the third comparative pressure pad 5 , and whether or not a problem occurs as the resistor is reduced in the amount of electrical resistance was checked. The problem with which the inventors of the present invention were concerned was as follows: if a pressure pad is lower in the amount of electrical resistance than a certain value, the voltage applied to the transfer station of an image forming apparatus is allowed to flow to the ground through the fixing device of the apparatus, causing the transfer voltage to drop, causing thereby the apparatus to output an defective image, the defects of which are attributable to transfer error. Incidentally, it has been known that a sheet of recording medium (paper) which was left unattended for a substantial length of time in an ambience which was high in both temperature and humidity is low in volume resistivity, and therefore, is likely to allow transfer current to flow into a fixing device, making it therefore likely to cause an image forming apparatus to output a defective image, the defects of which is attributable to transfer error.
[0063] At this point in time, the mechanism which causes an image forming apparatus to suffer from transfer error is described with reference to FIGS. 5 and 6 . First, referring to FIG. 5 , designated by a referential numeral 102 is a photosensitive drum as an image bearing member, and designated by a referential numeral 106 is a transfer roller as a transferring means. Designated by referential numerals 1 and 5 are fixation roller and pressure pad, respectively. Further, designated by a referential numeral 44 is a current limiting resistor which is in connection to the fixing device to prevent the image forming apparatus to output a defective image, the defects of which is attributable to unsatisfactory transfer. A toner image is formed on the photosensitive drum 102 by an unshown image forming means, and is transferred onto a sheet of recording medium by the application of voltage to the transfer roller 106 by an electrical power source 45 . The voltage applied to the transfer roller 106 is opposite in polarity to the toner.
[0064] Shown in FIG. 6 is a circuit which is equivalent to the electrical circuitry of the fixing device shown in FIG. 5 . In FIG. 6 , the photosensitive drum 102 is represented by the combination ( 53 ) of a resistor and a condenser, whereas the transfer roller 106 is represented by a resistor 54 . Assuming that the amount by which current is provided from the power source 55 remains the same, as the sum of the electrical resistance 56 of the sheet of recording medium, electrical resistance 57 of the pressure pad 5 , and electrical resistance of the current limiting resistor 58 reduces, a point A of the equivalent circuit, which corresponds in position to where toner is transferred onto a sheet of recording medium, reduces in potential level. As a result, the point A reduces in the amount of electrostatic force which attracts toner to a sheet of recording medium, causing therefore the image forming apparatus to output a defective image, the defects of which are attributable to the unsatisfactory transfer of toner onto the sheet of recording medium.
[0065] In the case of each of the pressure pads in the fifth and sixth embodiments, and the third comparative pressure pad, a substance concocted by dispersing carbon particles in a mixture of PEEK resin and PFA resin was used as the material for the recording medium backing layer of the pressure pad. The amount of electrical resistance of each of these pressure pads was measured with the use of a method similar to the one used to measure the amount of electrical resistance of the pressure pad in the first embodiment. The measured amount of electrical resistance of each pressure pad was 5 kΩ.
[0066] In the fifth embodiment, the resistors 44 ( FIG. 6 ), which is 5 MΩ in the amount of electrical resistance, was connected between the pressure pad 5 and GND. In the sixth embodiment, the resistor 44 ( FIG. 6 ), which is 1 MΩ in the amount of electrical resistance was connected between the pressure pad 5 and GND. In the case of the third comparative pressure pad, a resistor 44 which is 100 kΩ in the amount of electrical resistance was connected between the pressure pad and GND. In the tests, a sheet of Business 4024 (product of Xerox Co., Ltd.: 75 g/m 2 in basis weight) was reduced in the volume resistivity by being left unattended in an ambience which was high in both temperature (32.5° C.) and humidity (80% RH), and a solid black image, which is large enough to cover the entirety of this sheet was printed on this sheet. Then, the sheet was conveyed through the fixing device to check whether or not the image forming apparatus would output a defective image, the defects of which are attributable to unsatisfactory image transfer. The results of the tests are given in Table 2.
[0000]
TABLE 2
100 kΩ
5 MΩ
1 MΩ
Comparative
Resistance
Embodiment 5
Embodiment 6
Ex. 3
Properness
G
F
NG
of transfer
[0067] In Table 2, “G” indicates that there were no problems attributable to unsatisfactory image transfer, and “F” indicates that the apparatus outputted slightly defective images, the defects of which are attributable to unsatisfactory image transfer, but are not problematic for normal usage. Further, “NG” indicates that the image forming apparatus outputted defective images, the defects of which are serious. It is evident from the test results given in Table 2 that in order to prevent the formation of a defective image, the defects of which are attributable to unsatisfactory image transfer, the sum of the electrical resistance of the pressure pad and the electrical resistance of the current limiting resistor is desired to be no less than 1 MΩ, preferably, 5 MΩ.
[0068] As is evident from the above given description of the first to sixth embodiments of the present invention, and the first to third comparative pressure pads, the electrical resistance of the pressure pad is desired to be no more than 10 12 Ω. Further, it is in a case where a fixing device is such that the sum of the electrical resistance of its pressure pad, and the electrical resistance of its current limiting resistor connected between the pressure pad and GND, is no less than 1 MΩ that the fixing device can enable an image forming apparatus to output satisfactory images, and also, does not fail to properly nip a sheet of recording medium. In other words, the sum of the electrical resistance of the pressure applying member (pressure pad) and that of the current limiting resistor is desired to be no less than 10 6 Ω and no more than 10 12 Ω.
[0069] In these embodiments, only a resistor was connected between the pressure pad and GND to limit the amount by which electrical current flows from the transfer station to GND. However, the means for limiting the amount of this current does not need to be limit to a resistor. That is, it may be any electrical element or circuit as long as it is capable of limiting this current.
(Fourth Comparative Pressure Pad)
[0070] The recording medium backing layer of the fourth comparative pressure pad is plated with a metallic substance. More concretely, the substrate of this pressure pad is a piece of zinc-coated steel plate, which is the same as the one in the first embodiment. The recording medium backing layer of the pressure pad is a piece of 0.3 mm thick plate of SUS 304 plated with nickel. The recording medium backing layer was solidly attached to substrate with the use of adhesive. The pressure pad was set in a laser beam printer which is similar to the one in the first embodiment.
[0071] The fourth comparative pressure pad also was subjected to the same tests as those used to test the preceding pressure pads. The first 100 sheets of recording medium were normally conveyed through the fixing device. Thereafter, however, it became difficult for the sheets to be conveyed through the fixing device: paper jam frequently occurred. After the tests, the fixing device was disassembled to examine the surface of the pressure pad 5 . The examination revealed the presence of toner particles having adhered to the surface. Thus, it seemed reasonable to think that not only did these toner particles having adhered to the surface of the pressure pad 5 interfere with the recording medium conveyance, but also, frequently caused paper jam.
[0072] It is evident from the results of the above described tests that it is only a pressure pad, the recording medium backing layer of which is electrically conductive, that can make it possible to provide a fixing device which is satisfactorily durable in terms of recording sheet nipping performance and recording medium conveyance performance.
Embodiment 7
[0073] FIG. 7 is a sectional view of the pressure pad in the seventh preferred embodiment of the present invention. The pressure pad in this embodiment is similar to the one in the first embodiment in that in terms of the recording medium conveyance direction, the upstream portion (relative to the fixation nip) of the recording medium backing layer of its pressure pad, which is responsible for the nipping of a sheet of recording medium, is electrically conductive as is the counterpart in the first embodiment. In this embodiment, however, the downstream portion of the pressure pad is electrically nonconductive. That is, in this embodiment, the upstream and downstream portions of the recording medium backing layer of the pressure pad are made different in function in order to further improve the pressure pad in recording medium conveyance performance. More specifically, the upstream portion of the recording medium backing layer of the pressure pad relative to the nip, is formed of electrically conductive resin. That is, in terms of the recording medium conveyance direction, the upstream portion of the recording medium backing layer of the pressure pad, relative to the fixation nip which the pressure applying member forms between itself and the rotational heating member, is formed of a mixture of resin, and particles of electrically conductive substance dispersed in the resin. In comparison, the downstream portion of the recording medium backing layer of the pressure pad in this embodiment, in terms of the recording medium conveyance direction, relative to the fixation nip, is formed of a resinous substance which is greater in volume resistivity than the upstream portion.
[0074] On the entrance side of the fixation nip, what is important in the performance of a fixing device is nipping of a sheet of recording medium. Therefore, the upstream portion of the recording medium backing layer of the pressure pad needs to be higher in electrical conductivity, whereas on the exit side of a fixation nip, a sheet of recording medium is strongly and persistently pushed by the fixation roller, and therefore, the downstream portion of the recording medium backing layer of the pressure pad is not necessarily required to be electrically conductive. With the employment of this structural arrangement described above, it is ensured that a sheet of recording medium is reliably discharged while being kept flat on the recording medium backing layer of the pressure pad by the electrostatic force. On the other hand, on the downstream side of the fixation nip, such paper jam that is attributable to the wrapping of a sheet of recording medium around the fixation roller is of more serious concern.
[0075] To sum up the characteristic features of this embodiment, in order to ensure that a sheet of recording medium is properly nipped by the fixation nip, the upstream portion of the recording medium backing layer of the pressure pad relative to the fixation nip is made electrically conductive, whereas the downstream portion of the recording medium backing layer is made electrically nonconductive, in order to keep a sheet of recording medium flat on the recording medium backing layer by the electrostatic force to prevent the sheet of recording medium from wrapping around the fixation roller.
[0076] The recording medium backing layer of the pressure pad 5 in this embodiment is similar to the counterpart in the first embodiment except for a minor difference. That is, in terms of the recording medium conveyance direction, the downstream portion 52 a of the recording medium backing layer 52 in this embodiment is different from the upstream portion 52 b in that the former is formed of an electrically conductive substance, such as the one used in the fourth embodiment, created by dispersing carbon particles in PEEK resin, whereas the latter is formed of plain PEEK resin, which is electrically nonconductive. Further, a resistor which is 5 MΩ in electrical resistance was connected as a current limiting resistor to the fixing device.
[0077] The following test was performed to find out how easily a sheet of recording medium is likely to wrap around the fixation roller, on the exit side of the fixing device. That is, a solid black image which is large enough to cover a sheet of OHT (Overhead Projector Transparency: sheet of transparent resin) from one lateral edge of the sheet to the other was printed on a sheet of OHT in such a manner that the leading edge of the solid black image would be 50 mm away from the leading edge of the sheet. Then, the sheet was conveyed through the fixing device. In the case of the fixing device in the first embodiment, the fixing device was jammed by the sheet as the sheet wrapped around the fixation roller 1 , whereas the fixing device in this embodiment was not jammed by the sheet of OHT, proving that the fixing device in this embodiment is superior in recording medium conveyance to the fixing devices in the first embodiment.
[0078] In each of the first to seventh embodiment of the present invention, the material for the substrate of the pressure pad was metallic. However, the substrate may be formed of electrically conductive resin, as an integral part of a one-piece pressure pad, with absolutely no ill effect. In a case where the substrate is formed as an integral part of a pressure pad, the entrance guide and exit guide of a fixing guide also may be formed as integral parts of a pressure pad so that the pressure pad can double as the sheet guiding members of a fixing device. With the employment of such a structural arrangement, it is possible to provide a fixing device which is more accurate in the positioning of the recording medium conveyance guides, and therefore, can more reliably convey a sheet of recording medium than any of the fixing devices in the preceding embodiments.
[0079] Further, a pressure pad, such as the pressure pad 5 in the seventh embodiment, the entrance side of which relative to the fixation nip is different in electrical resistance from its exit side, may be formed by combining two sub-components molded of a resinous substance, which are different in electrical resistance. In addition, such a pressure pad may be structured so that it doubles as the entrance guide and exit guide of a fixing device.
[0080] In the seventh embodiment, in terms of the recording medium conveyance direction, the upstream portion of the recording medium backing layer of the pressure pad relative to the fixation nip was electrically conductive, whereas the downstream portion was dielectric. However, the seventh embodiment is not intended to limit the present invention in scope. That is, all that is necessary to prevent a sheet of recording medium from wrapping around the fixation roller is to design a pressure pad so that the downstream portion of the recording medium backing layer of the pressure pad, in terms of the recording medium conveyance direction, is greater in the amount of electrical resistance than the upstream portion.
[0081] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0082] This application claims priority from Japanese Patent Application No. 206633/2010 filed Sep. 15, 2010 which is hereby incorporated by reference. | An image heating device includes a heating rotatable member; and a pressing pad contacted to said heating rotatable member and forming a nip with said heating rotatable member to nip and feed a recording material, said pressing member being provided with an electroconductive material dispersed resin material layer contacting said heating rotatable member. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a distribution system for foods that must be essentially cold-insulated during transport, for example, frozen foods such as frozen sea foods, chilled foods and cooled foods, foods to be preferably cold-insulated, and various other commodities, which are generally called commodities requiring cold packing in this specification.
2. Description of the Prior Art
Various commodities requiring cold packing as described above are accommodated in cold insulation boxes with thermal insulation capability such as styrene foam boxes together with a cold insulating material such as ice or dry ice, and transported using, for example, refrigerating vans and thermally insulated vans, in order to prevent the deterioration of quality otherwise caused by temperature rise. This practice is widely employed.
For example, JP9-170860A (Japanese patent document) discloses a method for transporting commodities requiring cold packing, using an insulated van in which a liquefied gas such as liquid carbonic acid gas or liquid nitrogen gas is injected for supply into a space formed above a snow receiver installed above an enclosed container accommodating the commodities requiring cold packing, for quickly cooling the interior of the space. In the quick cooling method as described above, if liquid carbonic acid gas is injected at room temperature, for example, 47% of it becomes snow dry ice while the remaining 53% becomes gas. Since the weight of carbonic acid gas is about 1.5 times the weight of air, it stays at a low place.
Furthermore, JP11-236077A (Japanese patent document) discloses a cold insulation box used for transporting perishable food, which can accommodate perishable food together with a cold insulating material without damaging the perishable food, and in which since the cold air generated by the cold insulating material is not suddenly applied to the perishable food, the perishable food can be uniformly cooled without being partially discolored. As for the cold insulation box for transport, particularly, a cold insulation sheet produced by vapor-depositing a metal on one or both sides of a foamable cushioning sheet or by sticking a metal foil or a metal vapor-deposited film is placed in the cold insulation box, and a cold insulating material is accommodated on one side of the cold insulation sheet while perishable food is accommodated on the other side, to ensure that the perishable food can be kept in contact with the metal-deposited side or the metal foil-stuck side or the metal vapor-deposited film-stuck side of the cold insulation sheet. In this case, as the cold insulating material, ice or dry ice or any of various cold reserving materials can be used, and frozen food itself can also be used as the cold insulating material.
The problem arising when ice is used as the cold insulating material is that water is generated due to thawing. Furthermore, in the case where dry ice is used as the cold insulating material, there arise the following problems.
1. When dry ice is handled, thick protective gloves must be worn, and sufficient ventilation is necessary to avoid oxygen deficiency, while a special container for storing it is necessary, to inconvenience working efforts.
2. Dry ice has a temperature as very low as −78.5° C., and a latent heat of 132.4 kcal/g. However, since the temperature is very different from room temperature, the duration of effective cold insulation is relatively short. Furthermore, when the commodities requiring cold packing are, for example, foods, the working temperature may be lower than the optimum temperature, and in this case, the quality may be deteriorated.
3. The production cost of dry ice is, for example, about 72.5 yen/kg, and since it can be used only once, the cost is so high that it does not allow the distribution cost to be lowered.
Furthermore, in the case where dry ice or ice is used as a cold insulating material, the duration of effective cold insulation is not long enough. So, somewhere in the distribution route from the package packing facility through the distribution facility to customers, the cold insulation boxes must be opened for being re-charged with the cold insulating material. This threatens to undermine the quality and safety of the commodities requiring cold packing.
In view of the above problems, in distribution of commodities requiring cold packing, the social demand for any other cold insulating material than dry ice is sharply growing.
However, in the case where a soft or hard container filled with a cold insulating agent such as a liquid in standard ambient temperature is used repetitively as a cold insulating material, the following problems arise.
1. Since a cold insulating material as much as 3 times the usually used amount must be kept in stock, the storage space and stock volume must be managed with additional expenses needed for them.
2. Since it is essential to wash and sterilize the cold insulating material to keep it clean whenever it has been used, additional expenses are needed for the equipment and personnel.
3. In the case where the cold reserving material is deteriorated due to temporal change, it must be disposed as waste with additional expenses needed for it.
4. If the container is inferior, it can be damaged after repetitive use, and the cold insulating material contained in it may leak dangerously. If the cold insulating material contains a toxic substance such as ethylene glycol, it is dangerous, and furthermore, there arises such a problem that a fungus, for example, a mold is generated.
On the other hand, also with regard to the cold insulation boxes, conventional simple boxes made of styrene foam or the like are used mostly only once since it is difficult to re-use them. This is undesirable waste of a resource.
SUMMARY OF THE INVENTION
The object of this invention is to solve the above-mentioned problems.
To solve the above-mentioned problems, the present invention proposes a system for distributing the commodities requiring cold packing, comprising a package packing facility for accommodating the commodities requiring cold packing, into repetitively usable cold insulation boxes together with a repetitively usable cold insulating material, to establish packages, a distribution facility for stacking the packed packages for distribution to customers, a renewing facility for renewing the used cold insulating material and the used cold insulation boxes to allow their reuse, and a stock facility for stocking the renewed cold insulating material and the renewed cold insulation boxes.
This invention also proposes said distribution system, wherein the renewing facility and the stock facility are provided in the same space as that of the package packing facility.
This invention also proposes said distribution system, wherein the renewing facility and the stock facility are provided to be common to plural package packing facilities.
This invention also proposes said distribution system, wherein the repetitively usable cold insulating material is anti-freezing enclosed containers respectively filled with a hygroscopic polymer-based cold insulating material.
This invention also proposes said distribution system, wherein the repetitively usable cold insulation boxes are made of polypropylene foam.
This invention also proposes said distribution system, wherein the repetitively usable cold insulation boxes are made of a plastic composite resin foam.
This invention also proposes said distribution system, wherein each of the repetitively usable cold insulation boxes is a box with a multi-layer structure consisting of an outer structural material and an inner thermally insulating material.
This invention also proposes said distribution system, wherein the cold insulating material and the cold insulation boxes are rentable.
This invention also proposes said distribution system, wherein in the case where the cold insulating material and the cold insulation boxes are rentable and where the renewing facility and the stock facility are provided to be common to plural package packing facilities, the rental agent manages the renewing facility and the stock facility.
This invention also proposes said distribution system, wherein each of the cold insulation boxes consists of a box body and a cover, and opening action proving tapes are stuck to straddle the box body and the cover coupled with each other. Furthermore, this invention proposes that each of the opening action proving tapes has its one end pre-fixed to either the cover or the box body; the other end of the tape has a portion to be bonded to the other member; and a region of the portion to be bonded at the other end is differently adhesive for allowing a performed opening action to be proved.
According to the distribution system of this invention described above, the packages, each of which has the commodities requiring cold packing accommodated in a cold insulation box together with a cold insulating material in the package packing facility, are at first transported to the distribution facility in the region of customers, and then they are transported from the distribution facility to the customers.
At each of the customers, the commodities requiring cold packing such as frozen foods or chilled foods in the cold insulation boxes are delivered, and the cold insulation boxes and the cold insulating material are recovered and brought back to the distribution facility.
The cold insulation boxes and the cold insulating material recovered to the distribution facility are transported to the renewing facility and respectively washed and sterilized by the washers installed there, then being transported to and stored at the stock facility.
In this case, the cold insulating material is quickly frozen by a freezer installed at the renewing facility or stock facility, and stored in a frozen state.
The cold insulation boxes and the cold insulating material stored in the stock facility as described above are supplied to the package packing facility as required and used again for distributing the commodities requiring cold packing.
The cold insulation boxes and cold insulating material, the quantities of which change depending on the distribution volume of the commodities requiring cold packing as described above, can be owned by the distributor concerned. However, it is very convenient if they are rentable.
In this case, if the rental agent concerned manages the renewing facility and the stock facility together with the cold insulation boxes and the cold insulating material, the distributor concerned can also be highly benefited.
On the other hand, if the renewing facility and the stock facility are provided in such a manner that the cold insulation boxes and the cold insulating material can be supplied commonly to the package packing facilities of plural distributors, the distribution volumes of the cold insulation boxes and the cold insulating material can be averaged advantageously for the rental agent.
Meanwhile, the renewing facility and the stock facility can be located in the same space as that of the package packing facility, and in this case, the distributor can also manage the renewing facility and the stock facility.
If the repetitively usable cold insulating material is anti-freezing enclosed containers respectively filled with a hygroscopic polymer-based cold insulating agent, the temperature can be set in response to the commodities requiring cold packing, and the temperature difference from room temperature can be made smaller compared with that of dry ice. So, the commodities can be kept cold for a long period of time. Furthermore, since the freezing and storing temperature can be kept higher than that of dry ice, freezing and storage can be facilitated.
In this invention, in the constitution in which opening action proving tapes are stuck to straddle the box body and the cover of each of the cold insulation boxes, if the cover is opened somewhere in said distribution route, the fact of opening can be confirmed, and if a predetermined action is taken in this case, the safety of the commodity requiring cold packing can be enhanced.
For example, as for each of the opening action proving tapes, if one end of it is pre-fixed to either the cover or the box body while the other end has a portion to be bonded to the other member, the sticking work at the package packing facility is easy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a systematic illustration for explaining simplified distribution routes in the system for distributing the commodities requiring cold packing of this invention, as a first example with processed marine products as the commodities requiring cold packing.
FIG. 2 is a systematic illustration for explaining simplified distribution routes in the system for distributing the commodities requiring cold packing of this invention, as a second example with processed marine products as the commodities requiring cold packing.
FIG. 3 is a perspective view showing an example of a cold insulation box used in the system for distributing the commodities requiring cold packing of this invention.
FIG. 4 is a perspective view showing a state in which opening action proving tapes are stuck to a package having a predetermined commodity kept in the cold insulation box of FIG. 3 .
FIG. 5 is a perspective view showing a state in which the opening action proving tapes once removed from the state of FIG. 4 are stuck carefully to restore the state of FIG. 4 .
FIG. 6 is a sectional view showing an example of the opening action proving tapes.
FIG. 7 is a sectional view showing an example of the opening action proving tapes.
FIG. 8 is a sectional view showing an example of the opening action proving tapes.
FIG. 9 is a sectional view showing an example of the opening action proving tapes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The entire constitution of the system of this invention is explained below in reference to FIG. 1 showing a first example.
FIG. 1 is a systematic illustration for explaining simplified distribution routes in the system for distributing the commodities requiring cold packing of this invention, as a first example with processed marine products as the commodities requiring cold packing.
Symbol 1 denotes a producer. In this case, the producer can be a fishery company or the like who catches or cultures marine products as the raw materials of processed marine products, or a freezing company who processes the raw materials transported from a producer, for producing processed marine products as the commodities requiring cold packing 2 .
Symbol 3 denotes a package packing facility managed by a distributor. The package packing facility 3 is a facility in which the commodities requiring cold packing 2 are accommodated into cold insulation boxes 5 together with a cold insulating material 4 , to establish packages 6 .
In this case, the cold insulating material 4 and the cold insulation boxes 5 can be repetitively used as described later. Each of the cold insulation boxes 5 consists of a box body 5 a and a cover 5 b. Symbol 7 denotes a temperature data logger, and in this example, the temperature data logger 7 is accommodated in each of the cold insulation boxes 5 together with the commodity requiring cold packing 2 and the cold insulating material 4 , to establish the package 6 , so that the temperature in the cold insulation box 5 of the package 6 can be measured and recorded every set time period.
In this example, if the package 6 is established as described above, opening action proving tapes 15 are stuck to straddle the box body and the cover provided as the members of the cold insulation box, and the tapes are described later in detail in reference to FIGS. 3 to 9 .
The distribution components described above are particularly explained below. At first, as the repetitively usable cold insulating material 4 , for example, anti-freezing enclosed containers respectively filled with a hydroscopic polymer-based cold insulating agent can be used.
Each of the repetitively usable cold insulation boxes 5 can be, for example, a container having a cover and made of polypropylene foam, or a container having a cover and made of a plastic composite resin foam. The latter plastic composite resin foam is, for example, a composite resin foam consisting of polystyrene and polyethylene, and it is a functional plastic foam having both the stiffness of polystyrene and the viscosity of polyethylene. For example, a material called “Piocelan (registered trademark)” can be used.
The cold insulation box 5 made of the above-mentioned plastic foam is suitable as a component of the system of this invention, since it is excellent in cold insulation, durability, washing property, etc.
Furthermore, the repetitively usable cold insulation box 5 can also be a box with a multi-layer structure consisting of an outer stiff structural material and an inner thermally insulating material, namely, with a structure called “cooler box.”
The process for distributing the packages 6 established as described above is explained below.
The packages 6 packed in the package packing facility 3 as described above are, at first, distributed by the transport means 8 of the distributor to a distribution facility 9 corresponding to a region of customers such as a regional distribution center. In the drawing, arrow lines indicate the transport movement and directions. Solid arrow lines indicate the movement of commodities requiring cold packing 2 , and broken arrow lines indicate the movement of distribution components such as the cold insulation boxes 5 and the cold insulating material 4 . Furthermore, in the drawing, each oval 10 covering both a solid arrow line and a broken arrow line indicates a state in which the commodity requiring cold packing 2 and the distribution components are integrated, i.e., a packed state.
The packages 6 transported from the package packing facility 3 to the distribution facility 9 and stacked there as described above are then distributed to customers 11 a, 11 b and 11 c such as retail shops, and unpacked there, to deliver the commodities requiring cold packing 2 such as frozen foods or chilled foods contained in the cold insulation boxes 5 , and to recover the cold insulation boxes 5 and the cold insulating material 4 for bringing them back to the distribution facility 9 . In the case where the temperature data loggers 7 are placed in the cold insulation boxes 5 , they are sent to the managing company, etc.
The cold insulation boxes 5 and the cold insulating material 4 recovered from the customers 11 to the distribution facility 9 are then transported to a renewing facility 12 and washed and sterilized by respective washers (not shown in the drawing) installed there, then being transported to a stock facility 13 , to be stored there. In this case, the cold insulating material 4 is quickly cooled by a freezer (not shown in the drawing) installed in the renewing facility 12 or the stock facility 13 , and are stored in the stock facility 13 in a frozen state. The renewing facility 12 and the stock facility 13 can be provided separately, but can also be provided integrally as a renewing and stock facility 14 .
The cold insulation boxes 5 and the cold insulating material stored in the stock facility 13 are supplied to the package packing facility 3 as required and used again for distributing the commodities requiring cold packing 2 .
The cold insulation boxes and the cold insulating material, the quantities of which change depending on the distribution volume of the commodities requiring cold packing, can be owned by the distributor concerned, but it is very advantageous if they are rentable. In this case, if the rental agent concerned manages also the renewing facility 12 and the stock facility 13 or the renewing and stock facility 14 together with the cold insulation boxes 5 and the cold insulating material 4 , the distributor can also be highly benefited.
In the above example, the renewing facility 12 and the stock facility 13 or the renewing and stock facility 14 is located at a position apart from the package packing facility 3 , but can also be located in the space as or adjacent to or near that of the package packing facility 3 as the case may be, and the distributor per se can also manage them.
FIG. 2 shows the entire composition of the system of this invention as a second example.
In said distribution system of the second example, a renewing facility 12 and a stock facility 13 are provided as facilities common to plural producers 1 a and 1 b, plural package packing facilities 3 a and 3 b and plural distribution facilities 9 a and 9 b. The other constitution is the same as that of the first example. So, the corresponding components are given the same symbols to avoid double explanation.
In said distribution system of this example, as described above, the renewing facility 12 and the stock facility 13 are provided as facilities common to plural package packing facilities 3 a and 3 b and plural distribution facilities 9 a and 9 b, and a cold insulating material 4 and cold insulation boxes 5 are rentable. The rental agent manages the renewing facility 12 and the stock facility 13 .
In the constitution of the above system, the packages 6 , obtained by accommodating the commodities requiring cold packing 2 transported from the producers 1 a and 1 b, into the cold insulation boxes 5 together with the cold insulating material 4 in the respective package packing facilities 3 a and 3 b, are at first transported to the distribution facilities 9 a and 9 b corresponding to the regions of customers 11 a, 11 b, 11 c, 11 d, . . . , and subsequently, they are transported from the respective distribution facilities 9 a and 9 b to the customers 11 , 11 b, 11 c and 11 d.
As described before, the commodities requiring cold packing 2 such as frozen or chilled foods in the cold insulation boxes 5 are delivered to the customers 11 a, 11 b, 11 c and 11 d, and the cold insulation boxes 5 and the cold insulating material 4 are recovered and brought back to the respective distribution facilities 9 a and 9 b. Then, the cold insulation boxes 5 and the cold insulating material 4 recovered to the respective distribution facilities 9 a and 9 b are transported to a common renewing facility 12 and respectively washed and sterilized by the washers installed there, then being transported to and stored in a stock facility 13 . The cold insulation boxes 5 and the cold insulating material 4 stored in the stock facility 13 are supplied to the respective package packing facilities 3 a and 3 b as required, for being used for distributing the commodities requiring cold packing 2 .
Since the above-mentioned constitution allows the distribution volumes of the cold insulation boxes 5 and the cold insulating material 4 to be averaged, it is advantageous for the rental agent.
As described above, the renewing facility 12 and the stock facility 13 or the renewing and stock facility 14 can be located at an adequate place, and unlike the above-mentioned example, they can also be located in the same space as or adjacent to or near that of the distribution facility 9 a or 9 b, and the number of facilities can also be selected as desired.
The opening action proving tapes 15 are described below in reference to FIGS. 3 to 9 .
As shown in the drawings, each of the opening action proving tapes 15 has an adhesive layer 17 provided on the back side of a transparent or light-transmitting tape proper 16 , and one end of it is pre-stuck to the cover 5 b while the other end not stuck to the box body 5 a has a portion 18 on the back of the tape proper 16 . The portion 18 is more adhesive to the adhesive layer 17 but can be separated from the other region. The portion 18 is illustrated as a flat form in the example, but it is actually a disc. Furthermore, the adhesive layer 17 on the back of the tape proper 16 at the other end is covered with releasing paper 19 , for being protected till it is used.
In the above constitution, the commodity requiring cold packing 2 is accommodated in the cold insulation box 5 together with the cold insulating material 4 , and the cover 5 b is coupled with the box body 5 a, to establish the package 6 . Then, from each of the opening action proving tapes, the releasing paper 19 is removed, and the adhesive layer 17 is stuck to the box body 5 a, for distribution in this state.
The work of sticking the opening action proving tape 15 is carried out additionally when the package 6 is established. However, since one end of the opening action proving tape 15 is pre-stuck to the cover 5 b, the work of sticking the opening action proving tape 15 is merely to remove the releasing paper 19 at the other end and to stick the other end to the box body. So, the work is easy.
With regard to the opening action proving tape 15 to be stuck to the package 6 as described above, if the tape is not used without sticking the other end as shown in FIG. 3 , or if the tape is merely stuck to the package 6 , the portion 18 that is not separated from the other region is invisible.
However, if one end of the opening action proving tape 15 once stuck is removed as shown in FIG. 8 , the portion 18 that is more highly adhesive to the adhesive layer 17 than to the other region is separated from the other region of the tape proper 16 , to remain on the box body 5 a.
Therefore, in the case where the opening action proving tape 15 is stuck again to the box body 5 a in this state, even if it is carefully tried to let the other region of the tape proper 16 suit the portion 18 , it is actually difficult. After all, the border between them is clearly visible.
Therefore, even if the opening action proving tape 15 once removed to open the cover 5 b is carefully stuck again in an attempt to make the tape look like a tape that has never been removed before, the portion 18 is clearly visible in distinction from the other region. So, the once removed opening action proving tape 15 cannot be stuck to look like a tape that has never been removed before.
Thus, in the case where the cover is opened somewhere during distribution, this fact can be confirmed according to this invention, and if any predetermined action is taken in this case, the safety of the commodity requiring cold packing can be enhanced.
In the above-mentioned example of the system, the opening action proving tapes 15 are stuck to the package 6 . However, for example, in the case where a box with a multi-layer structure consisting of an outer stiff structural member and an inner thermally insulating material, that is, a structure called a cooler box as described before is used together with a cover having a locking mechanism, it is not necessary to use the opening action proving tapes 15 .
INDUSTRIAL APPLICABILITY
This invention as described above provides the following numerous advantages in the distribution of commodities requiring cold packing.
1. Presently cold insulation boxes are used only once since it is difficult to re-use them. However, in this invention, since they can be washed and sterilized for being renewed to allow repetitive use, sanitation is assured and wasteful consumption of resources can be avoided while the problem of waste can be solved.
2. Since ice or dry ice is not used as the cold insulating material, the problems involved in the use of them as described before can be solved.
3. If anti-freezing enclosed containers respectively filled with a hygroscopic polymer-based cold insulating agent are used as the cold insulating material, the temperature can be set in response to the commodities requiring cold packing, and the temperature difference from room temperature can be kept smaller than that of dry ice. So, the effect of cold insulation can be maintained for a long period of time. Furthermore, since the freezing and storing temperature can also be elevated compared with that of dry ice, freezing and storage can be facilitated. For these reasons, it is not necessary at all that the cold insulation boxes are opened for being re-charged with the cold insulating material somewhere in the distribution route from the package packing facility through the distribution facility to customers, unlike the case of using dry ice or ice as the cold insulating material.
4. Since it is not necessary to open the cold insulation boxes somewhere in the distribution route from the package packing facility through the distribution facility to the customers as described above, the quality of the accommodated commodities requiring cold packing can be positively maintained.
5. Additionally in this invention, in the case where a cover is opened during distribution, the fact of opening can be confirmed. So, a predetermined action can be taken to very highly enhance the safety of the commodity requiring cold packing.
6. If the cold insulation boxes and the cold insulating material, the distribution volumes of which change in response to the distribution volume of the commodities requiring cold packing, are made rentable, and the rental agent manages the renewing facility and the stock facility, then it is not necessary that the distributor manages the cold insulation boxes, the cold insulating material and the facilities. So, the distributor can greatly enjoy the advantage of lower risk.
7. If the cold insulation boxes and the cold insulating material are supplied from the renewing facility and the stock facility to the package packing facilities of plural distributors, the distribution volumes of the cold insulation boxes and the cold insulating material can be averaged advantageously. | A system for distributing commodities such as foods requiring cold packing, such as frozen sea foods, chilled foods, cooled foods, etc., in disposable cold insulation boxes which can use ice and/or dry ice to cool these foods. This system comprises a packing facility for packaging commodities, into repetitively usable cold insulation boxes together with a repetitively usable cold insulating material, to produce cooled packages, a distribution facility for stacking resultant cooled packages for distribution to customers, a renewing facility for renewing used cold insulating material and used cold insulation boxes to facilitate their reuse, and a stock facility for stocking the renewed cold insulating material and the renewed cold insulation boxes, as components of the system, wherein each of the cold insulation boxes consists of a box body and a cover, and opening action proving tapes are stuck to straddle the body box and cover to couple them together. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit to Provisional Application No. 60/626,443 filed Nov. 10, 2004, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel scaffolding apparatus and method that provides enhanced productivity and safety. The present invention provides an apparatus comprising a frame scaffold with a self-propelled mechanically-operated sliding support, as well as methods of assembling, using and disassembling a frame scaffold using the sliding support. In addition to its safety and efficiency enhancements, the apparatus does not require the support of an additional structure (i.e., it is self-supporting), thus allowing for a wide variety of uses that are unavailable to other scaffolding systems. The apparatus is a highly cost effective and flexible system.
BACKGROUND OF THE INVENTION
[0003] Every year numerous fatalities and serious injuries occur in the construction and building industry as a result of workers using many of the scaffolding systems that are widely available today. In particular, many workers are injured or killed when they fall during assembly of the scaffold. In addition to the issue of worker safety, the cost to businesses, and particularly small to mid-size contractors in the industry, of the significant safety deficiencies of many commonly used scaffolding systems is substantial.
[0004] Despite these safety issues, the need for some type of scaffolding systems is undeniable. As the working level of a structure rises above the reach of crew members on the ground, scaffolding systems, which are essentially temporary elevated platforms, are erected to support the crew members, their tools, and materials. Building construction and repair require scaffold both for internal use as well as for external use in order to permit workers to stand at an elevation above ground surface to do work on areas of a building that is not accessible otherwise. For instance, a scaffold system is utilized in the installation of aluminum siding, or applying a coat of paint on the exterior of buildings.
[0005] There are many different types of scaffold systems in use today. For example, two general types of scaffold in use are suspended scaffolds and supported scaffolds. Suspended scaffolds are platforms suspended by ropes, or other non-rigid means, from an overhead structure. Many of the fatalities and injuries due to workers falling, associated with scaffold systems in general, are due to suspended scaffolds in particular.
[0006] In general, simple frame scaffolds are structurally safer and more efficient than suspended scaffolds. Supported scaffolds generally include one or more platforms supported by outrigger beams, brackets, poles, legs, uprights, posts, frames, or similar rigid support. Supported scaffolds comprise frame or fabricated, mobile, tube and coupler and pole scaffolds. Supported scaffold systems range from simple frame scaffolds to highly complex systems which may incorporate a motorized lift system.
[0007] Where complex support scaffold systems would be cost prohibitive for small and mid-sized contractors, a simple frame scaffold is desirable. Fabricated frame scaffolds, for example, are perhaps the most common type of scaffold because they are versatile, economical, and easy to use. They are frequently used in one or two tiers by residential contractors or small commercial and office contractors. However, frame scaffolds are often difficult and time-consuming to erect, largely because of their reliance on manual assembly. As such, they also place workers at substantial risk, particularly during assembly.
[0008] Manual assembly commonly requires individual hanger brackets to be lifted off of supports on the frame scaffold by a worker and moved up to another set of supports. This requires the heavy wood planks on top of the hangers to be removed or lifted so the bracket may be removed and placed in a new position. This exposes several workers to either crushing injuries or falls. The crushing injury often results from the planks slamming down on the bracket or falling completely from the scaffold. A fall typically occurs when a worker goes off balance while moving the hanger bracket or planks.
[0009] Further, the individual hanger brackets are spaced approximately three feet apart, so the brackets may only be moved in 3-foot increments. This is highly restrictive. Workers are typically forced to improvise as the structure approaches a ceiling or soffit of a building or other overhead obstruction that presents an obstacle to raising the boards. This compromises efficiency, productivity and worker safety.
[0010] Various other forms of scaffolding are also problematic. For example, a ladder jack scaffold is a simple device consisting of a platform resting on brackets attached to a ladder. Ladder jacks are limited to very light applications. Tube and coupler scaffolds are so-named because they are built from tubing connected by coupling devices, such scaffold systems are cost-prohibitive for small construction companies. Due to their strength, they are frequently used where heavy loads need to be carried, or where multiple platforms must reach several stories high. Their versatility, which enables them to be assembled in multiple directions in a variety of settings, also makes them hard to build correctly. Pole scaffolds are a type of supported scaffold in which every structural component, from uprights to braces to platforms, is made of wood.
[0011] Mobile scaffolds are a type of supported scaffold set on wheels or casters, they are designed to be easily moved and are commonly used in jobs like painting and plastering, where workers must frequently change positions. The brackets are designed to be raised and lowered in a manner similar to an automobile jack. However, mobile scaffolds are restricted to low levels and thus are very limited in usefulness.
[0012] Pump jack systems represent an alternative to some of the scaffold systems described above. The pump jacks typically include support arms that hold planks on which the workers can stand on when moving up and down along the pump jack poles. FIG. 1 is an illustration of a scaffold system that utilizes pump jacks in which pump jack poles are anchored on the ground by pole anchors and attached to the wall of the structure that the work is being done on, by pump jack braces for support. Pump jacks are operated to move up and down the pump jack poles to the desired height. The worker raises the pump jacks up with the foot, and lowers it by hand-cranking it down with a handle. A platform, e.g. a plank is supported between the jacks, and its height is adjusted by pumping the jacks and hand-cranking a handle. For example, one such scaffold that has been previously disclosed in the literature is depicted in FIG. 1 , which is provided merely for comparison. As shown in the Figure, the pump jack system is physically attached to the wall of a structure (other than a scaffold structure itself, and has pump jack poles that are 30 feet or lower in height.
[0013] Thus, current pump jack systems are restricted to certain applications because they must be secured to a wall or other structure for support. Moreover, pump jacks cannot be used by heavy contractors because they lack material storage capability. Pump jack systems only provide support for workers and some miscellaneous small tools. They also lack guardrails or fall protection for the workers. Therefore, the pump jack systems are highly limited in their usefulness.
[0014] Accordingly, most of the previously available systems which are in wide use today are deficient in terms of safety, efficiency, affordability or some combination thereof. Therefore, it would be highly desirable to have a scaffold system that remedies these deficiencies. In particular, it would be desirable to have a scaffold system that cost effectively mechanizes the process of assembling frame scaffolding, instead of relying upon inefficient and dangerous manual assembly. Further, it would be highly desirable to have a scaffold system that is not limited to movement of the brackets in three foot increments, but instead allows unlimited movement to maximize flexibility and easily allow the scaffolding to be adapted to any overhead environment.
[0015] The present inventions overcomes the deficiencies of previously disclosed scaffolding systems, by providing independently-supported scaffold system that allow a wide variety of uses, and by extending the height of the pump jack poles for the purposes of utilizing such a scaffold system in a variety of structures, the present invention also overcomes the cost associated in setting up large scaffold systems, the safety issues associated with suspended scaffolds, the inefficient, and time-consuming manner required to securing the scaffold system to a structure. The present invention provides all of the benefits of previously available systems without comprising on safety. Further, this is accomplished by the present invention in a simple, cost-effective manner as required by small and mid-sized contractors. Moreover, the present invention provides a more efficient system that allows for faster assembly and disassembly of the scaffolding.
SUMMARY OF THE INVENTION
[0016] The present invention provides a method and apparatus for a frame scaffold system. The present invention as described herein provides a reduction in the cost associated in setting up scaffold systems, the injuries and fatalities due workers falling, and the time required to securing the scaffold system to a structure.
[0017] An embodiment of the present invention utilizes apparatus that comprise at least one pair of opposable scaffold frames, wherein the at least one pair of opposable scaffold frames are being supported by at least one support brace; at least one vertical member coupled to the at least one pair of opposable scaffold frames by at least one clamp member; at least one sliding assembly moveable along the at least one vertical member, said at least one sliding assembly comprising a lever member operatively associated with a roller assembly, said roller assembly being engageably associated with the at least one vertical member; and at least one support surface rigidly affixed to the at least one sliding assembly.
[0018] In another embodiment of the present invention, it is disclosed a method and apparatus where a vertical member is coupled to a scaffold assembly; securing a mechanically-operable vertical member-sliding assembly unit to a portion of the scaffold assembly with a clamp member; and assembling the scaffold assembly while mechanically operating the mechanically-operable vertical member-sliding assembly unit to ascend or descend the scaffold assembly.
[0019] In another embodiment of the present invention, it is disclosed herein an apparatus includes a scaffold assembly comprising multiple levels of pairs of opposable scaffold frames joined and supported by cross braces; and a pump jack operatively associated with said frame scaffold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 depicts a scaffold utilizing three pump jacks as disclosed on the website of Lynn Ladder for purposes of comparison with the present invention.
[0021] FIG. 2 depicts a side view of a two-pole frame scaffold utilizing pump jacks in accordance with an implementation of the present invention.
[0022] FIG. 3 is a frame scaffold system depicting opposable scaffold frames, a vertical member and a sliding assembly in accordance with an implementation of the present invention.
[0023] FIG. 4 is a frame scaffold system depicting opposable scaffold frames, a vertical member, a sliding assembly in accordance with an implementation of the present invention, and a work platform with a guardrail.
[0024] FIG. 5A depicts a top view of a clamp attachment to the scaffold in accordance with an implementation of the present invention.
[0025] FIG. 5B is an illustration of a T-rail in accordance with an implementation of the present invention.
[0026] FIG. 6 depicts a top view of a pump jack/attachment assembly showing its connection to the scaffold legs in accordance with an implementation of the present invention.
[0027] FIG. 7 depicts a pump jack as disclosed on the website of Lynn Ladder for the purposes of comparison with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The following description is intended to convey a thorough understanding of the invention by providing a number of specific embodiments and details involving the structure and operation of a novel apparatus of the present invention. It should be understood, however, that the present invention is not limited to these specific embodiments and details, which are provided for exemplary purposes only. It should be further understood that one possessing ordinary skill in the art, in light of known apparatuses and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending upon specific design and other needs.
[0029] The present invention provides a novel scaffold apparatus and method for efficiently, safely and cost-effectively assembling a frame scaffold system. Further, the present invention provides a scaffold apparatus, and method, that does not require any attachment to or support from another structure, hence, the apparatus is an independently-supported system. The present invention dramatically increases productivity and safety by mechanizing what was previously a completely manual process. The present invention does not rely on complex and expensive automatic or power source driven operation. In fact, no power source is required whatsoever. Only a moderate amount of force by the operator needs to be applied to operate the apparatus.
[0030] According to an embodiment of the present invention, as shown in reference to FIG. 2 , a partial cutaway view of a scaffold system 200 is provided. The partial cutaway view shows a portion of scaffold frames 202 a and 202 b joined to each other. As this is only a partial cutaway view, not shown are the support braces and the opposing scaffold frames that would correspond to the two illustrated scaffold frames 202 a and 202 b as would be understood by a person skilled in the art.
[0031] Referring still to FIG. 2 , vertical member 210 is operatively associated with sliding assembly 220 . Sliding assembly 220 includes a lever 222 which may be moved in a downward and/or upward motion by an operator (not shown), for example, by a pumping action with the operator's foot, such as to engage and disengage a roller assembly (not visible) with the vertical member 210 , which by force of friction allows the sliding assembly 220 to ride up and down the vertical member 220 and in close proximity to the scaffold frames 202 a and 202 b.
[0032] Referring still to FIG. 2 , the vertical member 210 is made of any suitable material in any suitable shape or form, for example, a rectangular hollow aluminum tube where a hollow cavity 240 , is indicated in the figure as a dotted line, and where a lower portion of the rectangular metal vertical member 244 has a connecting rail 246 that slides into the cavity of the upper portion 242 .
[0033] According to an embodiment of the present invention, the sliding assembly 220 comprises a pump jack. For example, an exemplary pump jack is provided merely for purposes of illustration, as described in the web site of FalconScaffolds, a pump jack manufacturer and seller. See also FIG. 7 herein. Further, the pump jack may be of the type disclosed in U.S. Pat. No. 4,463,828. More specifically, and according to an embodiment, the pump jack comprises a vertical frame portion to which a horizontal platform support arm is attached. The pump jack includes a lower shackle portion and an upper shackle portion, each of which surrounds a vertical member, such as vertical member 210 of FIG. 2 .
[0034] An upper roller portion, which provides a pivot support and which is attached to an upper clamping bracket surrounds the vertical member 210 . In order to raise the sliding assembly 220 of the present invention up the vertical members 210 , an operator places his foot on the lever 222 , pressing it in a downward motion any number of times until the desired height is achieved. When the platform is to be lowered, the operator disengages the upper shackle, and then operates a spring-loaded handle, by continuously applying an unwinding downward motion, thereby, lowering the sliding assembly 220 and the platform attached thereto to the desired height. The operator stands on the platform while operating the lever and also as a work platform, e.g. to lay cinderblock, etc. In this manner, the operator can move up and down the workface in any increment and with relative ease compared to previously available systems within a low to moderate budget range.
[0035] Referring again to FIG. 2 , the sliding assembly 220 , comprises a lever member 222 , operable by at least one operator in an upward and downward motion, and a roller assembly (not shown) to be engaged and disengaged with the vertical member 210 to allow the sliding assembly 220 to slide upward or downward along the vertical member 210 . The lever member 222 may be operated in an upward and downward motion in any manner by the operator. For example, the lever may be foot-operated, hand-operated, knee-operated and the like, without limitation. Preferably, the lever is a foot-operated system.
[0036] In accordance with an embodiment of the present invention, a frame scaffold system 300 is shown in FIG. 3 . Vertical support members 310 are provided and are themselves supported by a scaffolding structure 301 . At least one sliding assembly 320 , is placed on the vertical member 310 , having a lever member 322 , which is engaged and disengaged by an operator in order for it to be vertically movable in an upward and downward direction along the length of the vertical member 310 .
[0037] The sliding assembly 320 , also incorporates a mounting bracket 324 to support a work surface 340 . The work surface 340 provides a platform from which workers can stand or sit to perform various jobs, and also provides a platform for a person to operate the sliding assembly 320 . One embodiment of the present invention provides that the mounting bracket 324 is of a triangular shape and is supported in a cantilever fashion from the sliding member 320 . A work surface 340 is then preferably attached to the mounting bracket 324 by threaded fasteners (not shown), but may also be attached by clamps, welding, a combination thereof, or by other means known in the art.
[0038] Referring to FIG. 4 , the work surface 440 of the present invention also preferably incorporates a guardrail 442 . The guardrail 442 is preferably attached to the work surface 440 by threaded fasteners (not shown), but may also be attached by clamps, welding, a combination thereof, or by other means known in the art. With the guardrail 442 attached to the work surface 440 , the work surface 440 can be raised and lowered without disassembly of the guardrail 442 . The guardrail 442 may also incorporate a gate (not shown) to allow ease of entry to the work surface 440 . The guardrail may completely or partially encase the operator on the work platform, and in any manner, as safety and work conditions necessitate. A mounting bracket 424 is attached to the sliding assembly 420 and provides support for the work surface 440 .
[0039] Referring still to FIG. 4 , vertical support members 410 are provided and are themselves supported by a scaffolding structure 401 . At least one sliding assembly 420 , is placed on the vertical member 410 , having a lever member 422 , which is engaged and disengaged by an operator in order for it to be vertically movable in an upward and downward direction along the length of the vertical member 410 .
[0040] In accordance with an embodiment, the apparatus permits at least one individual and preferably two or more individuals to vertically ascend and/or descend along the perimeter of frame scaffold, in close proximity to the scaffold. Unlike the pre-determined increments of previously available systems, movement to an unlimited number of positions in enabled. This permits a maximum amount of flexibility, particularly in terms of adapting to various challenging overhead environments. At the same time, the system is highly cost-effective and thus practical for projects that do not have a budget for large and complex electrically-powered systems.
[0041] The vertical members as described herein and depicted in the figures may be of any type suitable for the purpose of the present invention. A wide variety of shapes and sizes would be suitable to achieve the desired effect, as would be known to persons of skill in the art. The primary criteria for the selection of the type of vertical member relates to compatibility with the sliding assembly. For example, the vertical member may be a T-frame, an I-frame, a square post, a triangular post, a round pole or combinations thereof. Preferably, the vertical member is a square aluminum tube or an aluminum T-rail.
[0042] Referring to FIG. 5 , embodiment A, a top view illustrates the coupling of a vertical member 505 (as represented by a T-rail, for example, without limitation) to scaffold legs 520 a and 520 b via clamp member 525 . The clamp member 525 is held together on one end by a pair of screws 510 that are threaded for ease of attachment and adjustment, and on the other end, the clamp member 525 surrounds and secures a pair of scaffold legs 520 . The clamp member 525 includes a hinge 515 to facilitate attachment and provide flexibility (e.g., based on various sizes, etc.). The vertical member 505 provides support for and allows a sliding assembly (not shown in the figure) to slide vertically upwards and downwards. FIG. 5 , embodiment B is a side view of a vertical member which in the figure is represented by a T-rail provided merely for illustrative purposes while not intending to be limiting thereto.
[0043] Referring to FIG. 6 , a T-rail 602 is attached to a pump jack 603 which is operatively associated with and adapted to said T-rail such that the pump jack 603 is able to slide vertically along said T-rail 602 . The T-rail 602 is also attached to clamp members 604 a and 604 b that surround and grip a pair of scaffold legs 601 a and 601 b to secure the T-rail 602 to the scaffold structure, thereby allowing the pump jack 603 to move upwards and downwards in proximity to the scaffold in accordance with an implementation of the present invention.
[0044] The invention now being fully described, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein. The foregoing describes the preferred embodiments of the present invention along with a number of possible alternatives. These embodiments, however, are merely for example and the invention is not restricted thereto. It will be recognized that various materials and modifications as to shape may be employed without departing from the invention described above, the scope of which is set forth in the following claims. | An apparatus comprising a frame scaffold with a mechanically operated sliding support, as well as methods of assembling, using and disassembling a frame scaffold using the sliding support are disclosed. The apparatus provides for at least one individual to vertically ascend and/or descend along the perimeter of frame scaffold by mechanical operation. The operator of the apparatus is in close proximity to the scaffold. The apparatus does not require the support of an additional structure (i.e., it is self-supporting). The apparatus provides improved safety and efficiency in the assembly and disassembly of frame scaffold. | 4 |
FIELD OF THE INVENTION
[0001] This invention relates to miniaturized elements and their manufacture using existing and adapted technologies. In particular, the invention relates to miniaturized elements manufactured on a substrate using known and adapted PCB manufacturing technologies.
BACKGROUND OF THE INVENTION
[0002] Printed circuit boards are known as a means of providing electrical interconnection between electronic components. Basically a PCB consists of an insulating substrate, commonly made of an epoxy resin fibreglass, coated with a conductive layer, usually copper, affixed to one or both sides. A circuit design engineer will determine the layout of the components and the required conductive interconnections, and the pattern of interconnections will be etched on the PCB, usually using a photomask to protect the selected connection paths from the etchant. The result is an insulating carrier board with a pattern of copper tracks defining the interconnections between the electronic components to be affixed to the board.
[0003] Multi-layer PCBs are also known, in which additional copper tracks are incorporated between two or more insulating layers. There may be many such layers. The tracks on different layers can be connected by the use of through-holes, called vias, which may be plated-through to provide electrical connection between the layers. PCB manufacturing facilities commonly use photo lithography, laminating and electroplating which are relatively inexpensive methods.
[0004] Micro-machine technology such as micro-electromechanical systems (MEMS) are a more recent development and are directed to producing very small scale devices compared to PCB dimensions, often having moving components. MEMS is based on silicon fabrication, and uses similar processes to those used to manufacture integrated circuits. One of the features of MEMS type manufacturing processes is that they are very specialized, requiring high precision techniques and specialized equipment. For example vapour deposition is a commonly used step in MEMS fabrication which is a relatively expensive step. Some inexpensive fabrication steps like laminating are inappropriate for MEMS fabrication because of the relatively brittle nature of the commonly used silicon wafer.
[0005] The article “Low cost technology for multilayer electroplated parts using laminated dry film resist” H. Lorenz, et al describes the formation of epitaxial gear moulds using multi layer photoresist in the field of MEMS technology.
[0006] U.S. Pat. No. 5,430,421 describes a technique for the relief of stress in the formation of a double armature reed relay for MEMS applications using electroplating methods. The technique described uses vapour deposition of a sacrificial conducting layer onto which the reed relay component is electrodeposited.
[0007] U.S. Pat. No. 6,040,748 describes a method for alleviating stress bending in a MEMS relay by increasing the thickness of the armature and reducing the cross section of an intermediate portion of the armature to maintain flexibility. The stress is greatest in the initially deposited layer, so increasing thickness reduces the unwanted curling effect due to the stress.
[0008] None of these prior publications disclose or suggest the use or adaptation of PCB fabrication processes to manufacture miniaturized devices. It is an object of this invention to provide a method of fabricating electro mechanical devices on PCB substrates using PCB equipment and adapted PCB techniques.
SUMMARY OF THE INVENTION
[0009] This invention is based on the insight that the technology used for printed circuit board manufacture can be adapted to the manufacture of on-board items other than conductive tracks. In particular, these techniques can be used to produce elements which are partly or wholly detached from the substrate. In some applications, the elements are designed to have one or more degrees of movement. In other applications, the elements may be intended to be mechanically fixed, but may be designed to be at least partially removed from contact with other material. An example of the latter is an air-core inductor. This device may have its ends electrically connected into a circuit, but the coil is suspended in a cavity.
[0010] This invention therefore provides a method of fabricating a miniaturized element on a PCB substrate using existing and adapted PCB fabrication processes to fabricate elements on a substrate, wherein one or more elements are partially or completely detached from the substrate while optionally retaining a working interrelationship with other elements on the substrate.
[0011] The elements may be formed by an additive process such as electroplating or chemical plating, or by a subtractive process, such as etching.
[0012] In one application, the element or an element preform is applied to a sacrificial release layer located between the element fabrication layer and another layer or the substrate, the release layer being subsequently removed when the element is sufficiently formed and/or attached. In conventional PCB methods sacrificial layers are not located beneath a formed element or between the element and the PCB substrate.
[0013] In the case where the release layer is conductive, the element may be wholly or partially formed onto the release layer by electroplating through a mask which permits some or all of the features of the element to be plated onto the release layer. In the case where the release layer is not conductive, a conductive seed layer is first deposited on the release layer, the mask applied and the element or parts of the element are electroplated onto the seed layer.
[0014] In an alternative embodiment, an element fabrication layer is formed on or glued to the release layer, masked, and the full or partial elements etched out of the element fabrication layer.
[0015] In a further embodiment, further elements or parts of elements are formed in association with or in contact with the previously formed elements or parts of elements.
[0016] In another embodiment of the invention, the release layer is processed to include the profile of a desired shape of an element or part of an element before the element is formed on the release layer.
[0017] In a still further embodiment; an element fabrication layer is preformed with the profile of an element or part of an element before the element fabrication layer is attached to the release layer.
[0018] In one embodiment where the element is to be partially detached, the element may be designed to move relatively to the substrate. Driving means may be provided to move the element. The driving means may be, for example, electromagnetic, electrostatic, thermal (bimorph, memory), electromechanical (piezo).
[0019] Preferably, the detachment is performed by the use of a release layer between the part of the element to be detached and the substrate.
[0020] The release layer is a sacrificial layer and may be made of, for example, a photoresist layer, a metal layer, or a laminated layer composed of two or more layers of sacrificial material.
[0021] Optionally the release layer will be coated on one or both sides with an adhesive.
[0022] In one embodiment, a partially cured glass/epoxy composite layer called prepreg is used as the adhesive layer to attach a release layer to a substrate. This process requires the application of elevated and pressures for an extended period of time.
[0023] In another embodiment, the release layer is a dry film photoresist. Normally, the photoresist film is coated on one side with an adhesive which may have a peel-off protective layer which is removed immediately before use to expose the adhesive. We have found that the photoresist material such as RISTON (a registered trade mark of E I Du Pont De Nemours and Company) or similar photoresists, when heated to above a predetermined temperature, forms a suitable adhesive for attachment to some release layers or element fabrication layers. An advantage of this process is that the attachment requires lower pressure to obtain adhesion than some other processes. Preferably the process can be carried out using heated rollers at a temperature in the region of 150° C. at a controlled roller.
[0024] In another alternative, the release layer may include a metal sheet. This may be affixed to the substrate using an adhesive or the dry photoresist
[0025] A sacrificial layer may be applied to the substrate and the element fabrication layer applied to the sacrificial layer. Preferably, the sacrificial layer is formed of a material which is either soluble or preferentially etched by a selected etchant in preference to the element fabrication layer. The element fabrication layer may use a direct element deposition process in which the elements are directly formed on the sacrificial layer (masking of the pattern), or the element fabrication layer may itself be applied as a complete layer, which is etched to leave the desired elements.
[0026] One or more of the element fabrication layers, or the underlying sacrificial layer on which an element fabrication layer is to be formed, may be preformed or partly preformed to facilitate the fabrication of the elements. For example the outline of the element may be pressed or stamped into the element fabrication layer to give the element a preferred shape before the supporting matrix of the element fabrication layer is etched. Alternatively, the elements may wholly or partially stamped out of the element fabrication layer and held together by a web or matrix before applying the element fabrication layer to the substrate. Alternatively, portions of the “waste” areas of the element fabrication layer may be cut away before attaching the layer to reduce the subsequent processing time. Similar techniques may be applied to the sacrificial layer to add a profile to the sacrificial layer where the element fabrication layer is to be formed on the sacrificial layer, eg, by electro or chemical deposition.
[0027] In another embodiment, the substrate is a multi-layer PCB.
[0028] The invention also contemplates an embodiment in which vias are provided in the substrate. In some applications, the vias are filled or lined with electrical and/or magnetic path material.
[0029] The techniques outlined above may be used to form miniature components that are at a larger scale than MEMS products but are able to be made using less expensive techniques.
[0030] The products formed will usually include a portion achored to the substrate and apportion that is free of the substrate such as:
[0031] Reed relays consisting of a reed cantilevered out from a post formed on a via of the PCB substrate
[0032] Accelerometers or motion sensors incorporating a mass mounted on a spring attached to the PCB substrate
[0033] Reflective mirrors or pixel elements free to move relative to the anchor point on the PCB substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1 shows the initial stages of a process according to an embodiment of the invention.
[0035] [0035]FIG. 2 shows a first alternative arrangement for connecting an element to the substrate.
[0036] [0036]FIG. 3 illustrates the main steps of of a process implementing an embodiment of the invention.
[0037] [0037]FIG. 4 shows the process of forming elements attached to plated-through vias.
[0038] [0038]FIG. 5 shows a section through a plated-through via.
[0039] [0039]FIG. 6 illustrates the main steps of a process of this invention for fabricating a micro relay component;
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0040] The invention will be described with reference to the drawings.
[0041] [0041]FIG. 1 shows a typical process for producing elements according to a first embodiment of the invention.
[0042] In step 1 . 1 , a substrate 1 is coated with a sacrificial layer 2 . The substrate may be made of a substance suitable for use in a PCB fabrication process. The sacrificial layer is selected for its amenability to being dissolved or etched in preference to the element fabrication layer and the substrate. The sacrificial layer may be, for example a soluble non-metallic layer, a plastic layer, a metal layer, or a laminate of metal and non-metal. In one embodiment the sacrificial layer is made of aluminium or zinc sheet which is glued to the substrate by a suitable adhesive.
[0043] In a particularly advantageous application, the aluminium sacrificial layer may be glued to the substrate by using a dry protoresist film as the adhesive layer. The normal adhesive face of the film may be used to attach the film to one surface, while the previously unknown “hot melt” adhesive quality of the film may be used to attach to the other surface. This process can be carried out with the use of a hot roller mechanism, pressing the three components (substrate, film, sacrificial layer sheet together) with a heated rolled. The combination of heat and pressure ensuring good bonding.
[0044] In step 1 . 2 , a layer of photoresist 3 is applied to the sacrificial layer 2 . This layer may be applied by known techniques. Preferably, a dry photoresist film is applied to the sacrificial layer by removing the adhesive protection and applying the film in the known manner.
[0045] In step 1 . 3 , the photoresist is masked (not shown) with the desired pattern, exposed to UV radiation in selected areas, 4 , to selectively harden the exposed photoresist.
[0046] In step 1 . 4 , the undeveloped resist is developed using known techniques, leaving the hardened areas 4 on the sacrificial layer 3 .
[0047] In step 1 . 5 , the material 5 to be used for the elements (left sloping diagonal shading) is applied, eg, by electroplating, the photoresist preventing the deposition in areas where the developed resist is present. There may be particular reasons for plating more than one type of material as the element fabrication layer. For example, a metal element may be provided with a thin layer of gold to improve characteristics such as electrical connectivity. The improvement of corrosion resistance is another example of an application in which more than one metal is used in the element. Another application is where it is desired to take advantage of different properties of different metals, such as magnetic susceptibility and electrical or thermal conductivity, or different rates of thermal expansion of different materials.
[0048] It should be noted that, where the sacrificial layer is non-conducting, a step of coating it with seed layer of conductive material would be used when the sacrificial layer is applied. This then enables a subsequent step of applying another layer such as the element fabrication layer to the sacrificial layer by electroplating.
[0049] In FIG. 2, a support member B is shown by way of illustrative example as an attachment between the elements and the substrate. Our preferred means of attaching the elements to the substrate is by the use of “posts” formed using extended plated through vias. This is described in more detail below with reference to FIGS. 5 & 6.
[0050] Returning to the illustrative example in FIG. 2. 1 , the developed photoresist is removed, eg, in a caustic solution. The right sloping diagonal shaded area is the rear wall of the cavity left by the developed photoresist when it is removed in the caustic bath. See discussion below of the plan view in FIG. 2. 3 . At this stage, the elements C 1 , C 2 , C 3 , are partially released, but are still attached to the sacrificial layer 2 and the transverse member B.
[0051] In step 1 . 7 , the sacrificial layer 2 is removed by dissolving in a solution which dissolves the sacrificial layer material 2 in preference to the element material 5 . This then frees the elements C 1 , C 2 , C 3 , so that they are only attached to the transverse member B.
[0052] [0052]FIG. 2. 3 and FIG. 2. 4 show plan and side views of the end result of the process shown in FIGS. 1. 1 to FIG. 2. 2 . As is best seen in the side elevation, the element C 1 is an overhanging element spaced a distance “d” above the substrate 1 . The plan view shows similar, progressively shorter, overhanging elements C 2 & C 3 . The elements C 1 , C 2 , and C 3 are affixed to the transverse element B, which is attached to the substrate 1 .
[0053] The formation of element B has not been discussed in detail, but it can readily be fabricated, for example, in a first step before step 1 . 1 to remove the part of the sacrificial layer under the B footprint, and then laying down a first stage of the same thickness as the sacrificial layer. The remainder of B is built up at the same time as the elements C 1 , C 2 , and C 3 are deposited.
[0054] As discussed more fully below, in an alternative to the provision of the support B, in some cases it may be preferable to provide plated-through holes (vias) which can be extended to a desired height above the substrate to act as supports for the elements. More complex shapes and additional layers may be constructed using this process. We will now consider the preparation of a pre-plated aluminium sheet with reference to FIGS. 3 & 4.
[0055] [0055]FIG. 3 illustrates the process steps for the preparation of a combined sacrificial layer and element fabrication layer in an alternative embodiment of the invention. Some of the preparatory and intermediate steps are not shown on FIG. 3.
[0056] With reference to FIG. 3, the process includes the following stages:
[0057] Stage 3 . 1 : Clean the aluminium used for the sacrificial or release layer.
[0058] Stage 3 . 2 (optionally) The surface of the aluminium is micro-etched promote adhesion during the plating process. At this stage, a cleaning step, not shown, may be used to remove unwanted material such as silicon produced by the earlier steps.
[0059] Stage 3 . 2 : Zinc plating is performed using the zincate electroless method. We have found that interposing a zinc layer between the aluminium and the nickel produces better results for some applications. This step is not required if the release layer is made of zinc.
[0060] Stage 3 . 4 : Rinse and dry process (not shown in FIG. 3) is performed.
[0061] Stage 3 . 5 : A photoresist layer is applied to the zinc, preferably using the dry film photoresist. This step is illustrated at stage 3 . 3 of FIG. 3.
[0062] Stage 3 . 6 : The photoresist is masked and exposed to UV light to selectively harden it. This stage is illustrated at 3 . 4 in FIG. 3.
[0063] Stage 3 . 7 : Remove the unexposed resist using a developer. This corresponds to FIG. 3. 5 .
[0064] Stage 4 . 8 : A gold layer is deposited by electroplating. This is usually a thin layer. The photoresist prevents deposition on the zinc except at the locations determined by the mask. This step is illustrated at 3 . 6 in FIG. 3.
[0065] An intermediate rinse step at this point is not shown.
[0066] Stage 3 . 9 : A layer of nickel is then deposited on the gold layer by electroplating. This corresponds to stage 3 . 7 in FIG. 3.
[0067] Stage 3 . 10 : A caustic strip is then used to remove the developed photoresist. This is illustrated at 3 . 8 in FIG. 4. The resulting nickel cantilever has a gold plating on the underside from Stage 3 . 9 . This may be useful, for example if it is desired to make electrical contact to this surface.
[0068] This process results in the formation of the elements C 13 , C 23 , C 33 , being formed on the sacrificial release layer consisting of a zinc and aluminium laminate. This combination can now be applied to a substrate, eg, by using the dry film photoresist adhesive process described above. The advantage of using this adhesive process becomes clear when it is realized that the lower pressure and temperature conditions of this adhesion process reduce the probability of damage to the structure formed on the sacrificial release layer.
[0069] In an alternative embodiment, a further process may be added, eg, by adding a further layer to part of one or more of the elements. An additional photo-mask is applied over the composite, preferably before the caustic strip process shown at step 3 . 10 . The photoresist is processed, and additional material is deposited in the required locations.
[0070] Turning now to the application of the pre-plated sacrificial layer to the substrate and the formation of extended support posts formed on plated through vias, this process is illustrated in FIGS. 4 & 5
[0071] As shown in FIG. 4. 1 , a prepreg (epoxy/glass) layer 41 is applied to a substrate, PCB 42 . The prepreg 41 optionally has holes predrilled.
[0072] [0072]FIG. 4. 2 shows the pre-plated aluminium sacrificial layer from FIG. 3. 8 , with the elements pre-formed on its surface, attached to the prepreg 41 . This attachment may be performed by a hot press operation in which the assembly is heated for a period of the order of 1 hour under pressure. This operation uses the prepreg as an adhesive layer to attach the pre-plated aluminium layer.
[0073] [0073]FIG. 4. 3 shows a plan view of the result of a number of subsequent operations to be described below.
[0074] When the assembly has cooled, effectively gluing the prepreg and the pre-plated aluminium together, holes H 12 , H 22 , and H 32 are drilled through the aluminium and the PCB.
[0075] The following process is a preferred method of plating the holes.
[0076] A stainless steel mask with openings corresponding to the locations of the holes is applied over the assembly, and a copper seed layer is vacuum deposited into the holes from the steel mask side.
[0077] The steel mask is removed, and a photoresist is then applied to the top of the assembly in the usual manner, openings being left corresponding to the location of the holes following the masking, exposure, development, and removal of unexposed resist steps.
[0078] Similarly the bottom surface (the PCB lower surface) is coated with photoresist, also leaving the holes open.
[0079] Nickel or other selected metal is then plated through the hole using an electroplating process onto the seed copper lining. The material selected for plating the holes may be chosen for its electrical conductivity and/or magnetic susceptibility. Nickel exhibits both properties.
[0080] The resist is then stripped, leaving the assembly shown in FIG. 4. 3 .
[0081] [0081]FIG. 5 shows the detail of a plated-through via, as an expanded partial view of a section through the line B′B″ in FIG. 4. 3 . The substrate is, in this example, a multi layer PCB having alternate conducting and/or magnetic layers 512 interspersed between insulating layers 511 the sacrificial release layer 52 is applied on top of the substrate, and a first deposition pattern is applied to form the elements C 1 etc. Preferably the deposition is nickel. The hole H 12 is then drilled through the element C 1 , the release layer 52 (which may optionally be predrilled), and the layers of the substrate.
[0082] In order to make it possible to electroplate the inside of the hole H 12 , a conductive seed layer 55 , for example of copper, is applied to the inside of the hole. In this case, an overlap of the seed layer with the top of the element C 1 improve adhesion between the plating in the via and the element. The seed layer may be formed by a vapour deposition, all areas where the seed layer is not required being masked. Alternatively, chemical deposition may be used. After the seed layer is formed, electrical contact is made with the seed layer, and the assembly is immersed in a plating bath. In order to improve the penetration of the plating material into the vias, relative motion may be applied between the plating solution and the assembly, axially in relation to the vias. This may be done by moving the board or by imparting flow to the plating solution.
[0083] When the elements are attached to their corresponding attachment points, the sacrificial release layer is dissolved. In one embodiment, the sacrificial release layer is aluminium. Instead of aluminium, other materials may be used for the release layer. Zinc or copper are other suitable metals which may be used.
[0084] In some applications, it may be desirable to enclose the elements in a cavity. This may be achieved by placing a spacer around the elements and bonding it to the substrate, and then bonding a lid onto the spacer. The spacer may enclose single elements, groups of elements in a single cavity, or all elements in a single cavity. Alternatively the lid may be another substrate or PCB.
[0085] [0085]FIG. 6 show the steps for preparing a micro relay component in which suspended cantilevers are attached to a multilayer circuit board. A relay of this type is disclosed in European patent specification 1241697.
[0086] Stage 6 . 1 Dry film photoresist is laminated to the upper surface of a clean, prefabricated multi layer printed circuit board. This board contains prefabricated vias or through holes which are electroplated with gold as the final step. (see FIG. 6. 1 ) A protective film is applied to the rear of the PCB to protect circuit tracks during the subsequent process steps.
[0087] Stage 6 . 2 Copper foil (typically 35 micrometers thick) is laminated to the top surface of the photoresist layer using a hot roll laminator at 105° C. Alignment holes are predrilled through the foil using pre existing alignment vias on the multi layer PCB as a guide. (see FIG. 6. 2 ).
[0088] Stage 6 . 3 A further dry film resist is applied to the upper surface of the copper foilusing a hot roll laminator. A photomask is applied and is photo exposed so that circular apertures are formed using the drilled alignment holes as guides. These apertures coincide with the locations of the support posts in the final structure and also coinside with the plated through vias on the underlying PCB.
[0089] Stage 6 . 4 The exposed copper is chemically etched with an etchant such as ammonium persulphate to form circular apertures in the sacrificial copper layer. (see FIG. 6. 3 ).
[0090] Stage 6 . 5 The thin film resist blocking the holes is removed with sodium carbonate solution. At this stage, depending on the design of the multilayer PCB the copper sacrifial layer is electrically connected to the PCB plated through vias, by contact pressure during lamination. (see FIG. 6. 4 ).
[0091] Stage 6 . 6 The upper photoresist layer is removed by caustic stripping.
[0092] Stage 6 . 7 A new layer of dry film resist is laminated to the upper surface. This surface is photopatterned with a new mask having the preferred cantilevered shape defined on it and then the pattern is developed. The ends of the cantilever pattern are collocated with the holes in the underlying copper layer. (see FIG. 6. 5 ).
[0093] Stage 6 . 8 The exposed cantilever patterns are electroplated with gold/nickel/gold to the desired thickness. (see FIG. 6. 6 ).
[0094] Stage 6 . 9 The upper resist layer is caustic stripped and a new dry film resist is re applied by lamination. A new layer is photopatterned to provide circular apertures coinciding with the locations of the support post holes.
[0095] Stage 6 . 10 A thicker nickel layer is electroplated to provide a strong support post. (see FIG. 6. 7 ).
[0096] Stage 6 . 11 The sacrificial copper layer is removed by preferential chemical etching using an etchant such as ammonium persulphate.
[0097] Stage 6 ; 12 The adhesive photoresist layer is removed by caustic stippping to reveal the final product with suspended gold plated cantilevers or actuators attached to the multilayer PCB by nickel posts. (see FIG. 6. 8 ).
[0098] These steps may be carried out to form an array of cantilevered reeds for use as an array of microrelays.
[0099] Those skilled in the art will realise that a number of PCB techniques have been adapted for novel uses in the above described process.
[0100] Stages 6 . 1 and 6 . 2 use the photo resist layer as an adhesive to bond the sacrificial copper layer to the PCB substrate
[0101] Electrical contact with the sacrificial layer is achieved in stage 6 . 5
[0102] The vias are electroplated to provide support posts for the cantilevered reeds in stage 6 . 10
[0103] In stages 6 . 11 and 6 . 12 gentler removal (as by soaking rather than spraying) of the sacrificial layer and the photoresist layer are required to avoid damaging the cantilevered structure.
[0104] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
[0105] The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto, without departing from the scope of the present invention. | A method of fabricating electromechanical devices such as micro relays on printed circuit boards. The method includes the deposition of an element of the component onto an electrically conducting sacrificial layer, which is subsequently removed to form a PCB component that is suspended above the PCB substrate. In one embodiment, the vias in a multilayer PCB are used as the anchor posts for the suspended component. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 10/663,511, filed Sep. 16, 2003 now U.S. Pat. No. 6,945,501.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to improvements in cable support structures and more particularly pertains to new and improved apparatus for suspending digital voice and data cables in office buildings.
2. Description of the Prior Art
Digital voice and data communication cables used to interconnect computers and related digital equipment in office buildings, for the most, part require straight unconvoluted runs with the cables separated from power lines and other interference generating structures in order to avoid band-width deterioration.
As a result, the prior art has developed separate digital cable hangers. An example of several different types of cable hangers utilized in the prior art is shown in FIGS. 1 , 2 and 3 .
FIG. 1 illustrates a cable hanger 11 which is adapted for attachment to a metal support beam 13 . The operative end of the cable hanger is a bridle ring 15 that threads into a U-shaped fastening block 23 that is held to a steel beam 13 by a fastening screw 25 threaded through fastening block 23 . The bridle ring 15 has a plastic saddle 17 attached to the loop portion of bridle ring 15 by bosses 19 located on the underside of saddle 17 , that squeeze the curved portion of the saddle ring 15 . A digital cable bundle 21 is placed within the loop of saddle ring 15 on saddle 17 .
FIG. 2 illustrates another prior art cable hanger 27 which is designed to fasten into a ceiling or horizontal support by way of a nail 33 . The cable hanger 27 utilizes a straight length of wire rod 29 which is attached at one end to a clip 31 that also holds nail 33 and attached at the other end to a clip 35 which has a wire holding hook 38 . The hook 38 is fastened by way of rivets 39 to a metal saddle 37 . A bundle of wires or single digital communication cable would be placed within the saddle 37 .
Yet another digital communication cable holder prior art device is illustrated in FIG. 3 . A clip 41 cut out of flat metal has an upstanding portion 47 bent at a right angle into which a closed loop hook 45 is threaded. The clip 41 is held fast to a wire rod 29 by way of the pressure applied between the flat part of clip 41 and tabs 43 and the upstanding portion 47 .
The prior art digital voice and data communication cable hanging device 11 of FIG. 1 is not completely satisfactory in that the bridle ring is open, and the length or support height at which the digital communication cable 21 is suspended from the support is not adjustable.
The prior art digital communication cable hangers of FIGS. 2 and 3 have an adjustability feature. FIG. 2 , for example, shows a hook attached to wire 29 which can be moved up and down, and a bracket 31 holding nail 33 , which can be moved up and down. The prior art device of FIG. 3 shows a closed loop 45 attached to a bracket 41 which can be moved up and down rod 29 .
A shortcoming of the two prior art devices shown in FIGS. 2 and 3 is that the multiple parts used in the construction of the brackets that provide the adjustability, tend to create a structure that is flimsy, not capable of withstanding building movement caused by an earthquake, for example, and do not have a smooth, non-metallic wide surface loop or saddle that prevents kink and sags.
SUMMARY OF THE INVENTION
A digital voice/data communication cable hanger made of wire rod is shaped to be fastened to a concrete, wood, or metal overhead deck or side wall by an integral fastening loop at one end that provides a stabilizing footprint on the substrate. A cable support loop at the other end of the wire rod has a saddle integrally attached, for cradling the digital cable. The saddle is designed to close the cable support loop with a latch arm, after the cable is run through, to prevent the cable from slipping out. The hanger is preferably made from rigid wire rod by a double functioning spool which forms the fastening loop at one end and the support loop at the other end. The support loop is formed with the saddle attached to the wire rod. A second saddle designed to be selectively attached to the wire rod between its two ends may be used as needed for running additional digital cable.
BRIEF DESCRIPTION OF THE DRAWINGS
The exact nature of this invention, as well as its objects and advantages, will become readily apparent upon consideration of the following description of a preferred embodiment of the invention as illustrated in the accompanying sheets of drawings in which:
FIG. 1 is a perspective illustration of a prior art device.
FIG. 2 is a perspective illustration of an alternate prior art device.
FIG. 3 is a perspective illustration of yet another prior art device.
FIG. 4 is a perspective illustration of a preferred embodiment of the present invention.
FIG. 5 is a perspective illustration of a section of an alternate structure for the fastening loop.
FIG. 6 is a cross-sectional view showing how the fastening loop is attached to an overhead deck.
FIG. 7 is a side view showing how the fastening loop of FIG. 5 is attached to a side wall.
FIG. 8 is a side view of the cable support loop portion of the invention, for holding a digital communication cable.
FIG. 9 is an end plan view of an apparatus for making the small and large fastening loops on a communication cable support structure according to the present invention.
FIG. 10 is a side plan view of the apparatus of FIG. 9 shown making the large support loop on a communication cable support structure according the present invention.
FIG. 11 is a perspective illustration of the apparatus of FIG. 10 showing the formation of of the large support loop with intergral saddle on the shaft.
FIG. 12 is a side plan view of the apparatus of FIG. 9 showing use of the apparatus for forming the small fastening loop on an end of the shaft.
FIG. 13 is a perspective illustration showing the apparatus of FIG. 12 forming a right angle bend in the small fastening loop portion of the present invention.
FIG. 14 is a front plan view of a removable platform used to form the small closed fastening loop.
FIG. 15 is a perspective view of an alternate embodiment of the invention.
FIG. 16 is a side plan view with a partial section of part of the structure of FIG. 18 .
FIG. 17 is a front plan view of the cable holding mechanism of FIGS. 15 and 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of a communication digital audio/video cable support 51 , according to the present invention, is illustrated in FIG. 4 as comprising a metal shaft 53 which may be 8-gauge or higher, zinc plated mild steel rod, or similar shaft. The shaft 53 may be round, triangular or rectangular in shape, although round is preferred. For drop lengths greater than one foot, a 0.250 round steel rod having 65KSI tensile strength is preferred. The shaft 53 has a small loop 55 formed at its first end with a 90° bend just below the loop 55 for fastening the communication cable support structure 51 to a ceiling. The small loop 55 is the fastening loop.
The other or second end of shaft 53 is formed into larger loop 59 which has a saddle 57 of a very specific construction integral with the shaft 53 . As is more clearly shown in FIG. 8 , the saddle 57 has an integral sleeve 60 formed in the saddle. The saddle is preferably made out of plastic by an injection molded process. The sleeve 60 of saddle 57 extends from just before the shaft 53 starts to bend into a loop 59 and ends at the end 71 of the shaft 53 . The remaining portion 61 of the material of saddle 57 has no sleeve thereon, is flat, and extends to close the open space between the end 71 of shaft 59 and the straight shaft 53 . This flat part 61 of the saddle 57 has a notch 63 at its end to allow friction closure with shaft 53 . The flat part 61 of the saddle 57 is sufficiently flexible to rotate away from shaft 53 and open the loop 59 as required to place or remove wires from the support loop. The saddle is preferably a two inch to three and one-half inch closed loop made out of polypropylene resin or similar material.
FIG. 5 illustrates a fastening loop 65 without a bend in it. This fastening loop is utilized for attachment to overhead side walls 68 as shown in FIG. 7 . A fastener 67 like a timber pin for wood, or a ramset for concrete or a drill screw for a metal deck, for example, is held within the small fastening loop 65 by a collapsible bushing 69 on one side of the loop 65 and a washer 70 on the other side. The fastener 67 is driven into the vertical side wall surface 68 with a force sufficient to collapse bushing 69 so that the fastening loop 65 is flat against the vertical surface 68 . Bushing 69 is preferably made out of a light-weight plastic, nylon, or foam material.
For overhead attachments to horizontal decks, as shown in FIG. 6 , the 90° bend version of the cable support structure 51 is utilized. The fastener 67 , which may be a ramset or drill screw, for example, is held to the small fastening loop 55 by a bushing 69 on one side and a washer 70 on the other. Bushing 69 is made out of a plastic, nylon, or foam material that will collapse when the fastener 67 is driven fully into the horizontal surface 72 .
The unitary structure of the cable support 51 is a significant advantage when supporting digital video/audio cables in an environment where support sways and sturdiness is an important consideration.
The unitary construction of the communication cable support structure 51 also is of significant advantage from the standpoint of its manufacture, in that it can be made simply, quickly and cheaply by a simple hand-operated apparatus as shown in FIGS. 9-14 .
FIG. 9 shows the manufacturing apparatus 201 for making the cable support structure 51 having a spindle or spool 213 mounted for rotation about its central axis 210 . The spindle 213 is preferably made of steel in a drum shape, i.e. a generally cylindrical shape having first and second ends and a side of fixed diameter extending axially between the two ends. A shaft 215 fixed to one end of the spool 213 is a journal within a bearing casing 207 . A long-handled lever 211 is attached to the other end of shaft 215 by a pair of bolts 209 . Rotation of lever 211 causes spool 213 to rotate about its central axis 210 . Bearing casing 207 is held in position by a support wall 205 made of steel which is fixed to a sturdy base 243 .
Spool 213 has a steel arm 217 with an elongated portion and an elbow portion. The elongated portion extends parallel to the central axis 210 of spool 213 , as shown. Arm 217 is fastened by welding (or an equivalent fastening means) the elbow portion of arm 217 to an outer surface of the side of spool 213 so that the elongated portion of arm 217 rotates with spool 213 at a fixed radial distance from the central axis 210 .
A pair of pegs 219 and 221 are attached to the other end of spool 213 at an outer surface, as shown. One peg 219 is on the central axis 210 of the spool 213 . The other peg 221 is displaced a short distance from the central axis peg 219 . The distance between the two pegs is determined by the diameter of the shaft or rod 53 to be manipulated by the manufacturing apparatus 201 .
FIGS. 12 and 13 show the manufacturing apparatus 201 being used to make the small fastening loop 65 and 55 , respectively, at the first end of the shaft 53 . A platform 223 is mounted to the base 243 by a pair of pegs 225 that insert into matching apertures in the base 243 . This allows the platform to be removed during other operations of the apparatus 201 . Platform 223 has a surface lying along a line between central axis 210 and peg 221 for supporting shaft 53 when shaft 53 is inserted between the two pegs 219 and 221 on the end of the spool 213 . As shown in FIG. 12 , rotation of the long-handled lever 211 in a counterclockwise direction 202 causes the straight shaft end 229 to be bent into the closed loop 65 .
In order to place the 90° bend 234 ( FIG. 13 ) into the shaft 53 , the end of the shaft with a small fastening loop 65 is turned 90 degrees and again inserted between the pegs 219 and 221 . The long-handled lever 211 is rotated in a counterclockwise direction to a stop 225 which is threadably attached to the support wall 205 . This limited movement provides a 90° angle bend 234 in the shaft 53 , thereby converting a loop 65 into a loop 55 as required for attaching the cable support structure 51 to a horizontal overhead deck.
In order to form the large holding loop at the second end of the shaft 53 , the spool 213 is utilized as shown in FIGS. 10 and 11 .
Before the manufacturing apparatus 201 is utilized, the saddle 57 is slid on to the straight end of shaft 53 so that the support end 59 of shaft 53 slips into the entire length of the sleeve 60 that is an integral part of saddle 57 . The flat end 61 of the saddle continues beyond the end 71 of the shaft 59 in the saddle 57 . The still flat saddle with the shaft 53 attached is then inserted between the arm 217 and the spool 213 as shown in FIG. 10 .
Rotation of the long-handled lever 211 in a counterclockwise direction 247 causes the saddle 57 and the end 59 of the shaft 53 that is in the sleeve 60 of the saddle to bend into a loop as shown in FIG. 11 . The flat portion 61 of the saddle that extends beyond the end 71 is of sufficient length to close the open loop formed.
This manufacturing process described above, although hand operated, is fast and efficient, and produces a cable support structure 51 that is strong and rigid, capable of withstanding the forces exerted on it by the pulling of cable through the saddle supports and the forces exerted on it during overhead mounting to horizontal decks or walls. The length of the shaft 53 from the small fastening loop 55 to the large support loop in saddle 57 may vary in length. Preferably the cable support 51 comes in a variety of standard lengths to be used as needed for running the communication cable from an overhead support.
In those instances where additional cable needs to be run at some time after installation of the cable support structure 51 and at a different height than established by the cable support structure 51 , an additional saddle 227 may be mounted to shaft 53 along its midsection as shown in FIGS. 15 and 16 . Saddle 227 is constructed in the same manner as saddle 57 with a integral sleeve 229 formed in saddle 227 which contains a rod 230 that shapes saddle 227 by being bent into a loop, as shown in FIGS. 15 and 16 . The remaining portion of the saddle 231 which has no sleeve is flat and extends to close the open space between the straight shaft 53 and the end of the bent shaft 230 . The flat portion 231 of the saddle engages the flat side of the saddle 227 at the shaft 53 to provide complete closure of the saddle loop.
The saddle 227 is held to shaft 53 by a rod grasping mechanism 233 that has a pair of outside arms 237 and a pair of inside arms 239 . The rod grasping mechanism 233 as shown in FIGS. 16 and 17 is held fast to the saddle 227 by at least one rivet, or bolt or similar fastener 235 . The grasping mechanism 233 is preferably made out of a spring steel. It is shaped so that the rod 53 is grasped between an inside arm 239 and an outside arm 237 of the grasping mechanism 233 . Multiple arms are shown in the Figures because multiple arms are preferred to provide the additional holding force required. Although two holding arms are illustrated, more or less could be used, as needed. | A digital voice and/or data communication cable hanger provides a saddle support on a shaft fastened to a ceiling or beams or side wall by an integral fastening loop at one end. The other end of the hanger is shaped into a support loop for the cable. A saddle having the support shaft running through it closes the support loop to prevent cable from slipping out. The cable hanger is made by a tool using a rotating spool designed to shape the rigid shaft into a fastening loop at one end and a support loop at the other end. A second support loop can be selectively attached to the shaft between its ends. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of and claims priority from co-pending U.S. Application having Ser. No. 11/728,461, filed Mar. 26, 2007, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The disclosure herein relates generally to the field of severing a tubular member. More specifically, the present disclosure relates to an apparatus for cutting downhole tubulars. Yet more specifically, described herein is a method and apparatus for optimizing cutting tubulars wherein lubrication is maintained between the cutting member and the tubular.
[0004] 2. Description of Related Art
[0005] Tubular members, such as production tubing, coiled tubing, drill pipe, casing for wellbores, pipelines, structural supports, fluids handling apparatus, and other items having a hollow space can be severed from the inside by inserting a cutting device within the hollow space. As is well known, hydrocarbon producing wellbores are lined with tubular members, such as casing, that are cemented into place within the wellbore. Additional members such as packers and other similarly shaped well completion devices are also used in a wellbore environment and thus secured within a wellbore. From time to time, portions of such tubular devices may become unusable and require replacement. On the other hand, some tubular segments have a pre-determined lifetime and their removal may be anticipated during completion of the wellbore. Thus when it is determined that a tubular needs to be severed, either for repair, replacement, demolishment, or some other reason, a cutting tool can be inserted within the tubular, positioned for cutting at the desired location, and activated to make the cut. These cutters are typically outfitted with a blade or other cutting member for severing the tubular. In the case of a wellbore, where at least a portion of the casing is in a vertical orientation, the cutting tool is lowered into the casing to accomplish the cutting procedure.
BRIEF SUMMARY OF THE INVENTION
[0006] Disclosed herein is a cutting tool and method wherein lubrication is delivered during cutting. The system employs a rotating blade and a lubrication system for dispensing lubrication between the blade's cutting surface and the tubular to be cut. Optionally an isolation material may be included for retaining the lubrication in the cutting region. An example of a cutting tool includes a housing, a cutting member having a stowed position within the housing and a cutting position in cutting contact with the tubular, lubricant stored in a reservoir in the housing, a lubricant dispensing system having an inlet in fluid communication with the reservoir, an exit on the lubricant dispensing system that is sealed when the cutting member is in the stowed position, and open when the cutting member is in the cutting position, so that when the cutting member is in the cutting position lubricant can flow from the reservoir, through the lubricant dispensing system, and from the exit into the space between the cutting member and the downhole tubular. The cutting tool may optionally have a pressure source in pressure communication with the lubricant in the reservoir, so that when the exit on the lubricant dispensing system is open the lubricant is urged from the reservoir and out the exit. The cutting tool can also further include isolation material in a reservoir in the housing, a selectively openable passage between the reservoir and annulus between the cutting tool and the tubular, so that when the passage is opened the isolation material flows from the reservoir into the annulus to form a barrier hindering the lubricant from flowing away from the area where the cutting member contacts the tubular. A conduit may be in the cutting tool between the inlet and exit; also included can be a fastener coaxially coupled with the cutting member, wherein the exit mates with the fastener when the cutting member is in the stowed position to form a seal at the exit, and when the cutting member is in the cutting position the fastener is moved away from the exit thereby removing the seal from the exit allowing lubricant to flow through the conduit and out of the exit. A sealing plug may be slidingly disposed within the conduit that forms a seal in the conduit along its length and is pushed from the conduit by the lubricant when the seal is removed. The lubricant dispensing system can be a frangible conduit having an inlet in fluid communication with the reservoir, wherein the conduit is positioned so that when the cutting member moves from its stowed position to its cutting position it cutting contacts the frangible conduit to form an opening for lubricant to exit. Alternatively, the lubricant dispensing system includes a conduit depending from the exit, a sealing surface in the conduit, a seal element in the conduit in selective sealing engagement with the sealing surface, a portion of the seal element protruding past the exit and in the cutting member path as it moves from its stowed to cutting position, so that when the cutting member moves into its cutting position it contacts the seal element to push it away from the sealing surface to provide a fluid communication path between the reservoir and the exit. The cutting tool can be suspended from the surface on a conveyance member attached to the housing; a motor may be included in the housing coupled to the cutting member, and an anchor can be coupled with the housing having a deployed position in anchoring contact with the tubular. An electrical power supply can be provided at the surface connected to the conveyance member and a conducting member included between the conveyance member and the motor, so that power from the electrical power supply powers the motor.
[0007] Also disclosed herein is a method of cutting a downhole tubular that includes providing a tubular cutting device that includes a body, a cutting member moveable along a path from a stowed position within the body to a cutting position outside of the body, a supply of lubricant in the body, a lubricant dispensing system in fluid communication with the lubricant having a selectively openable exit, deploying the cutting device within the tubular; contacting the portion of the dispensing system with the cutting member by moving the cutting member from the stowed position to the cutting position, selectively opening the dispensing system exit with the cutting member so that lubricant flows from the exit and in the space adjacent the portion of the tubular to be cut, rotating the cutting member, and contacting the tubular with the rotating cutting member with the lubricant between the cutting member and the tubular.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0008] FIG. 1 . is a side view of an embodiment of a cutting tool in a tubular.
[0009] FIG. 2 is a side view of an alternative embodiment of a cutting tool in a tubular.
[0010] FIG. 3 is a side view of an alternative embodiment of a cutting tool in a tubular.
[0011] FIG. 4 a is a side view of a cutting tool having a lubrication system.
[0012] FIG. 4 b is a magnified side view of a cutting tool with a lubrication system.
[0013] FIG. 5 is an overhead view of a cutting blade having lubrication delivery ducts.
[0014] FIG. 6 is a partial cut away view of a cutting tool disposed in a cased wellbore.
[0015] FIG. 7 depicts in a perspective view a cutting tool with a lubricant sub.
[0016] FIGS. 8A , 8 B, 9 A, and 9 B depict in side schematic view a cutting member extending towards a cutting position and opening a discharge port for a lubricant.
[0017] FIG. 10 illustrates a side schematic view of an example of a cutting member moving into contact with a frangible conduit.
[0018] FIGS. 11 and 11A provide side schematic depictions of a cutting member moving into activating contact with a lubricant dispensing system.
[0019] FIGS. 12A and 12B depict in side sectional views an example of a lubricant dispensing system for use with a cutting tool.
[0020] FIG. 13 provides a perspective view of an example of a cutting tool with a cover.
[0021] FIGS. 14A-14C and 15 A- 15 B depict in perspective and sectional views an example of a lubricant dispensing system for use with a cutting tool.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
[0023] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the improvements herein described are therefore to be limited only by the scope of the appended claims.
[0024] Described herein is a method and apparatus for cutting and severing a tubular. While the apparatus and method described herein may be used to cut any type and length of tubular, one example of use involves severing tubing disposed within a wellbore, drill pipe, wellbore tubular devices, as well as wellbore casing. One embodiment of a cutting tool 10 as described herein is shown in side partial cut away view in FIG. 1 . In this embodiment, the cutting tool 10 comprises a body 11 disposed within a tubular 5 . As noted, the tubular 5 may be disposed within a hydrocarbon producing wellbore, thus in the cutting tool 10 may be vertically disposed within the wellbore tubular. Means for conveying the cutting tool 10 in and out of the wellbore include wireline, coiled tubing, slick line, among others. Other means may be used for disposing the cutting tool 10 within a particular tubular. Examples of these include drill pipe, line pigs, and tractor devices for locating the cutting tool 10 within the tubular 5 .
[0025] Included within the body 11 of the cutting tool 10 is a cutting member 12 shown pivotingly extending out from within the body 11 . A lubricant 18 is shown (in cross hatch symbology) disposed in the cutting zone 22 formed between the outer surface of the tool 10 and the inner surface 6 of the tubular 5 . For the purposes of discussion herein, the cutting zone 22 is designed as the region on the inner circumference of the tubular, as well as the annular space between the tool and the tubular proximate to the portion of the tubular that is being cut by the cutting tool. Examples of lubricants include hydrogenated polyolefins, esters, silicone, fluorocarbons, grease, graphite, molybdenum disulfide, molybdenum sulfide, polytetrafluoroethylene, animal oils, vegetable oils, mineral oils, and petroleum based oils.
[0026] Lubricant 18 inserted between the cutting member 12 and the inner surface 6 enhances tubular machining and cutting. The lubricant 18 may be injected through ports or nozzles 20 into the annular space between the tool 10 and the tubular 5 . These ports 20 are shown circumferentially arranged on the outer surface of the tool housing 11 . The size and spacing of these nozzles 20 need not be arranged as shown, but instead can be fashioned into other designs depending upon the conditions within the tubular as well as the type of lubricant used. As discussed in more detail below, a lubricant delivery system may be included with this device for storing and delivering the lubricant into the area between the cutting member and the tubular inner surface 6 . In many situations when disposing a cutting tool within a tubular, especially a vertically oriented tubular, lubricants may be quickly drawn away from where they are deposited by gravitational forces. Accordingly, proper lubrication during a cutting sequence is optimized when lubrication is maintained within the confines of the cutting zone 22 .
[0027] Additional ports 16 are shown disposed on the outer surface of the housing 11 for dispensing an isolation material 14 into the space between the tubular 5 and the tool 10 . The lubricant port 20 location with respect to the isolation port 16 location enables isolation material 14 to be injected on opposing sides of the lubricant 18 . Isolation material 14 being proximate to and/or surrounding the lubricant 18 retains it within or proximate to the cutting zone 22 . Referring again to FIG. 1 , isolation material 14 is disposed in the annular space between the tool 10 and the tubular 5 and on opposing ends of the lubricant 18 . Thus the isolation material should possess sufficient shear strength and viscosity to retain its shape between the tool 10 and the tubular and provide a retention support for the lubricant 18 .
[0028] Examples of isolation materials include a gel, a colloidal suspension, a polysaccharide gum, xanthan gum, and guar gum. One characteristic of suitable isolation material may include materials that are thixotropic, i.e. they may change their properties when external stresses are supplied to them. As such, the isolation material should have a certain amount of inherent shear strength, high viscosity, and surface tension in order retain its form within the annular space and provide a retaining force to maintain the lubricant in a selected area. Thus, as shown in FIG. 1 , the presence of the isolating material on opposite sides of the lubricant helps retain the lubricant within the cutting zone.
[0029] An alternative embodiment of a cutting tool 10 A within a tubular 5 is provided in side partial cross sectional area in FIG. 2 . In this embodiment, nozzles 16 are shown circumscribing the body 11 A outer surface along a single axial location on the tool 10 A. Optionally, in this situation, the nozzles 16 could be disposed on a side of the lubrication nozzles 20 opposite the cutting member 12 .
[0030] Shown in a side partial sectional view in FIG. 3 is another embodiment of a cutting tool 10 B coaxially deployed within a tubular 5 . In this embodiment the cutting member 12 B is a straight blade affixed to a portion of the body 11 B. Although in this embodiment a single set of nozzles 16 is shown for disposing isolation material 14 into the annular space between the cutting tool 10 B and the inner surface 6 of the tubular 5 , multiple sets of nozzles can be included with this embodiment along the length of the cutting tool 10 B. As shown, the lubricant 18 has been injected into the tubular 5 between the tool 10 B and the tubular inner surface 6 . Thus, the cutting zone 22 includes lubrication for enhancing any machining or cutting by the tool 10 B. Isolation material 14 is also injected into the annular space between the tool 10 B and the tubular thereby providing a retaining support for the lubricant 18 .
[0031] Another embodiment for delivering lubrication to a cutting surface is provided in FIGS. 4A and 4B . Here an example is provided of delivering a lubricant 18 to the cutting surface of a cutting blade by installing conduits within the blade itself. Shown in side partial sectional view in FIG. 4A is a cutting tool 10 C within a tubular 5 having a blade like cutting member 12 C radially extending from the body 11 C. Rotating the cutting tool 10 C while urging the cutting member 12 C into contact with the inner surface 6 cuts into the tubular 5 , and eventually severs the tubular 5 . Lubricant 18 is provided within a lubricant reservoir (not shown) disposed in the body 11 C. The reservoir is in fluid communication with the cutting member 12 C via supply line 24 shown extending into the cutting member 12 C. Lubricant 18 flows from the reservoir through the supply line 24 and exits the cutting member 12 C through a nozzle exit 26 formed at the supply line 24 terminal end. When discharged from the supply line 24 , the lubricant 18 enters the annular space between the cutting member 12 C and the inner surface 6 . This places the lubricant 18 on the cutting surface 27 of the cutting member 12 C reducing cutting friction thereby enhancing cutting operations. Lubricant 18 may be constantly supplied out into the nozzle exit 26 during a tubular 5 cutting procedure.
[0032] FIG. 5 provides an overhead view of one example of a cutting member 12 C that includes a blade 29 having conduits formed within its surface for delivering lubricant 18 to a cutting surface. In this embodiment, the cutting member 12 C includes inlays 28 on the blade 29 . Rotating the blade 29 about its axis A X and contacting a tubular with the moving inlays 28 can cut and sever a tubular. Lubricant supply lines 30 , shown in dashed outline, extend linearly along the blade 29 in opposite directions from the blade axis A X . The supply lines 30 terminate at exit nozzles 31 proximate each inlay 28 . Optimization of machining or cutting a tubular can occur by injecting lubricant from the exit nozzles 31 so lubricant is on the cutting surface during cutting. Optionally a nozzle could be formed on an inlay 28 so that lubricant 18 is added during the entire cutting sequence and is present between the cutting blade 29 and the cutting surface. For the purposes of discussion herein, cutting surface can be a surface in cutting contact, this includes the tubular inner surface 6 where it is being contacted by a cutting member as well as any portion of a cutting member or blade contacting a tubular during cutting.
[0033] FIG. 6 provides a partial side cut away view of an embodiment of a cutting system used in cutting a tubular 7 . In this embodiment a cutting tool 10 D is shown deployed from a conveyance member 8 into a cased wellbore 4 that intersects a subterranean formation 2 . The tubular 7 is coaxially disposed within the wellbore casing. Optionally, the cutting tool 10 D may be employed for cutting the wellbore casing and used in the same fashion it is used for cutting the tubular 7 . Examples of means used in deploying the tool 10 D in and out of the wellbore 4 by the conveyance member 8 include wireline, slick line, coil tubing, and any other known manner for disposing a tool within a wellbore. Shown included with the cutting tool 10 D is a controller 38 , a lubricant delivery system 40 , an isolation material delivery system 46 , and a cutting member 12 . The controller 38 , which may include an information handling system, is shown integral with the cutting tool 10 D and may be used for its control. The controller 38 may be configured to have preset commands stored therein, or can receive commands offsite or from another location via the conveyance member 8 . An optional anchoring system 32 is shown having anchor legs extending outward from the cutting tool 10 D into anchoring contact with the tubular 7 inner surface.
[0034] The lubricant delivery system 40 can be employed to deliver lubricant 18 within the space between the cutting member 12 and tubular 7 . The delivery system 40 shown includes a lubricant pressure system 42 in communication with a lubricant reservoir 44 . The pressure system 42 is adapted for conveying lubricant 18 from within the reservoir 44 through the tool 10 D and into the annular space between the cutting tool 10 D and the tubular 7 and adjacent the cutting member 12 . The pressure system 42 may be spring loaded, a motor driven pump, or include pressurized gas.
[0035] Further depicted with the cutting tool 10 D of FIG. 6 is an isolation material pressure supply 48 and an isolation material reservoir 50 that are included with the isolation material delivery system 46 . The isolation material pressure supply 48 , which can have a pump, spring loaded device, or compressed gas, may be used in urging isolation material 14 from within the isolation material reservoir 50 and out into the annular space between the tool 10 D and the tubular 7 . It should be pointed out that the isolation material 14 and lubricant 18 can be simultaneously ejected from the cutting tool 10 D. Optionally either the isolation material 14 or lubricant 18 may be delivered into the annular space before the other in sequential or time step fashion. As far as the amount of lubricant 18 or isolation material 14 delivered, it depends on the cutting tool 10 D and/or tubular 7 dimensions; it is believed it is well within the capabilities of those skilled in the art to design a system for delivering a proper amount of lubricant 18 as well as isolation material 14 .
[0036] As shown with the embodiment of FIG. 6 , the cutting member is in a cutting sequence for cutting the tubular 7 and isolation material 14 is shown retaining a quantity of lubricant 18 adjacent the cutting member 12 thereby maintaining the lubricant 18 in the space between the cutting member and the tubular 7 . A controller 34 disposed at surface may be employed for relaying commands to or otherwise controlling the cutting tool 10 D. The controller 34 may be a surface truck (not shown) disposed at the surface as well as any other currently known or later developed manner of controlling a wellbore tool from the surface. Included optionally is an information handling system 36 that may be coupled with the controller 34 either in the same location or via some communication either wireless or hardwire. Also illustrated schematically is a power supply 35 shown disposed on the surface above the wellbore 4 and in communication with the conveyance member 8 . The power supply 35 can selectively provide power to the cutting tool 10 D via the conveyance member 8 that can be used for controls and/or motors within the tool 10 D.
[0037] It should be pointed out that the exit nozzles can have the same cross sectional area as the supply lines leading up to these nozzles, similarly other types of nozzles can be employed, such as a spray nozzle having multiple orifices, as well as an orifice type arrangement where the cross sectional area at the exit is substantially reduced to either create a high velocity stream or to atomize the lubricant for more dispersed application of a lubricant.
[0038] Referring now to FIG. 7 , provided therein is a side perspective and partial sectional view of an embodiment of a cutting tool 52 . The cutting tool 52 shown is a generally elongated member having a cylindrical outer body or housing 54 . Within the housing 54 is a motor 56 coupled to a circular cutting member 58 on its lower end. A fastener 60 couples on the cutting member 58 lower surface coaxial with the cutting tool 52 . The fastener 60 may be a nut that is screwed onto a shaft (not shown) extending from the motor 56 . Optionally, a gearing system (not shown) may mechanically connect the motor 56 and cutting member 58 .
[0039] Below the cutting member 56 the housing 54 tapers into a frusto-conical section to define a nose portion 62 . A bore 64 is shown axially formed through the nose portion 62 and in alignment with the fastener 60 . A cylindrically shaped nozzle 66 is disposed in the bore 64 having an upper end in contact with the fastener 60 lower surface. The nozzle 66 lower most end juts into a cylindrically shaped lubricant sub 70 that is attached along the conically contoured nose portion 62 outer surface. The lubricant sub 70 is shown in sectional view as a generally hollow member having on its upper end a cylindrically shaped plug 72 that abuts the nose portion 62 lower end. A ferrule 74 shown coaxially within the plug 72 registers with a passage 68 coaxially formed through the nozzle 66 . A reservoir 76 is defined within an open space in the sub 70 that is below the plug 72 . Lubricant may be stored in the reservoir 76 for injection between the cutting member 58 and a tubular inner surface. As noted above, injection of the lubricant onto a cutting surface enhances the cutting deficiency of a cutting tool.
[0040] In the embodiment of FIG. 7 a pressure source is provided within the lubricant sub 70 depicted as a combination of a piston 78 and spring 80 . The piston 78 illustrated is a cylindrical element defining the reservoir 76 lower periphery. The spring 80 , which coils helically along the inner circumference of the sub 70 , has a lower end in contact with the lower most surface of a sub 70 in an upper end in contact with the piston 78 . Thus as lubricant is expelled from the reservoir 76 the spring 80 expands to urge the piston 76 upwards in the direction of the plug 72 . Other pressure means may be employed, such as compressed gas, an expandable bladder, and selectively openable ports adapted to receive wellbore fluid therein.
[0041] FIGS. 8A and 8B provide an enlarged view of a portion of the cutting tool 52 where it couples with the lubricant sub 70 . In these views shown is the passage 68 coaxially formed within the nozzle 66 and how it registers with a dispensing line 75 coaxially formed through the ferrule 74 . The combination of the dispensing lines 75 and passage 68 form a conduit adapted for flowing lubricant within the reservoir 76 out into the cutting space between the cutting member 58 in the tubular. More specifically, in FIG. 8A the nozzle 66 upper end is depicted in sealing contact with the fastener 60 bottom blocking the passage 68 exit.
[0042] Shown in FIG. 8B the cutting member 58 is moving into a cutting position by pivoting radially outward breaching sealing contact between the fastener 60 and nozzle 66 exit. Therefore lubricant within the reservoir 76 now has a clear path from the nozzle 66 exit and can flow from the reservoir, through the conduit, and out of the nozzle 66 exit. Once past the nozzle 66 exit the lubricant can make its way to between the cutting member 58 and tubular. A resilient member 69 is shown in the space between the nozzle 66 and ferrule 74 that provides an outwardly urging force maintaining the sealing contact between the nozzle 66 exit and fastener 60 . In an example the resilient member may be a spring.
[0043] FIGS. 9A and 9B respectively represent side schematic depictions of a cutting member 58 in a stowed position within the housing 54 and in a cutting position in cutting contact with a tubular. The cutting tool 52 embodiments shown in FIGS. 9A and 9B includes a dispensing line 75 representing a conduit for communicating fluid between the reservoir 76 and lubricant exit. The dispensing line 75 exit is shown in sealing contact with the fastener 60 lower surface. Further provided in the embodiments of FIGS. 9A and 9B is a sealing plug 77 slidingly disposed within the dispensing line 75 . The presence of the sealing plug 77 enhances the pressure seal between the lubricant within the reservoir 76 and ambient the dispensing line 75 . Referring now to FIG. 9B , the cutting member 58 and fastener 60 have moved radially outward from the tool 52 axis A X thereby removing contact between the exit from the dispensing line 75 and fastener 60 . This opens the dispensing line exit 75 allowing the flow of lubricant from the reservoir 76 , represented by arrows, through the dispensing line 75 and into the ambient space, where it can make its way or be directed into the space between the cutting element and tubular.
[0044] A schematic of an alternate cutting tool 52 A is provided in a side sectional view in FIG. 10 . In this embodiment, a lubricant reservoir 76 within the housing 54 is shown containing lubricant L providing a lubricant supply. A dispensing line 75 A provides fluid communication between the lubricant reservoir 76 and a frangible tube 82 shown disposed in the path between the cutting member 58 stowed position and its cutting position. The frangible tube 82 is formed from a material that can be ruptured or otherwise severed by cutting contact with the cutting member 58 . Moreover, the frangible tube 82 has a sealed terminal end. In the embodiment of FIG. 10 , the end is attached to a solid portion of the body 54 . Optionally, the frangible tube 82 can stand freely in the cutting member 58 path and have a closed end rather than attached to the body 54 . In the embodiment of FIG. 10 , the cutting member 58 which is in cutting rotation, cuts the frangible tube 82 to form an opening. The opening cut into the frangible tube 82 provides an exit for lubricant L within the reservoir 76 to be dispensed into the space outside of the housing 54 and onto the surface of the tubular to be cut by the cutting member 58 .
[0045] Shown in a side schematic partial sectional view in FIG. 11 is an alternate example of a cutting tool 52 B in accordance with the present disclosure. In the embodiment of FIG. 11 a dispensing unit 86 is shown in fluid communication with a dispensing line 75 B connected on an upstream end to the lubricant reservoir 76 . Contact between the cutting member 58 and a protruding portion of the dispensing unit 86 opens a fluid path between the lubricant reservoir 76 and the area outside the housing 54 . FIG. 11A shows in a side sectional view, an enlarged view of the dispensing unit 86 and its interaction with the cutting member 58 . The dispensing unit 86 includes a cylindrical hollow outer housing 88 , a spherical seal plug member 90 within the housing 88 , an annular lip 91 on the exit portion of the housing 88 , and a spring 92 in urging contact against the seal plug member 90 on the side opposite the annular lip 91 .
[0046] Referring back to FIG. 11 , a portion of the seal plug member 90 protrudes past the remaining elements in the dispensing unit 86 . In this configuration, the seal plug member 90 contacts the inner radius of the annular lip 91 urged upward by the spring 92 to create a sealing surface between the seal plug member and annular lip 91 . The dispensing unit 86 shown is configured so that a portion of the seal plug member 90 protrudes into the cutting member 58 path. Thus, as the cutting member 58 moves into its cutting position from its stowed position, it contacts the seal plug member 90 pushing it further inside the housing 88 and depressing the spring 92 . This unseats the seal plug member 90 from the annular lip 91 allowing lubricant from within the reservoir 76 to exit from within the housing 54 .
[0047] Shown in a side sectional view in FIGS. 12A and 12B is another embodiment of a lubricant to cutting surface delivery system. With reference to FIG. 12A , a bore 64 C extends through the nose portion 62 between the reservoir 76 and cavity 63 within the cutting tool 52 C. A threaded plug 65 is fastened within an end of the bore 64 C adjacent the reservoir 76 . An elongated piston like sealing plug 77 C is slidingly provided within the bore 64 C having a portion shown extending outside the bore 64 C and into the cavity 63 . The sealing plug 77 C outer surface is scored on its outer circumference to form a notch 79 and its upper end terminates at the fastener 60 lower surface. An extension 61 is shown depending downward from the fastener 60 lower surface to below the sealing plug 77 C upper end.
[0048] Both the bore 64 C and sealing plug 77 C diameters transition from a larger to a smaller diameter. In the configuration of FIG. 12A , the respective diameter transitions are at different locations to form an annular space 73 around a portion of the smaller diameter section of the sealing plug 77 C. Also in the bore 64 C is a spring 67 shown between the threaded plug 65 and sealing plug 77 C that forces the sealing plug 77 C upper end against the fastener 60 . Also included in this embodiment is a passage 71 bored through the nose portion 64 C with an end in fluid communication with the reservoir 76 and an opposite end connecting to the dispensing line 75 C. The dispensing line 75 C has an exit proximate the cutting member 58 . The passage 71 intersects the bore 64 C along a portion in which the plug 77 C is disposed. In the embodiment of FIG. 12A , a seal is formed along the area where the sealing plug 77 C contacts the passage 71 that blocks fluid communication between the reservoir 76 and dispensing line 75 C.
[0049] As the blade 58 is rotated and pivoted radially outward from the cavity 63 , the attached extension 61 collides with the sealing plug 77 C and applies a sufficient moment arm to fracture the sealing plug 77 C along the notch 79 . Referring now to FIG. 12B , removing the portion of the sealing plug 77 C above the notch 79 , allows the spring 67 to expand and upwardly urge the remaining section of sealing plug 77 C. This unseats the seal between the sealing plug 77 C and passage 71 thereby allowing lubricating fluid within the reservoir 76 to be communicated through the passage 71 , to the dispensing line 75 C, and then delivered to a cutting surface. The sealing plug 77 C is prevented from being ejected from the bore 64 C by contact between the diameter transitions on the bore 64 and sealing plug 77 C, thus eliminating the annular space 73 .
[0050] The present disclosure further includes using a cutting tool with a lubricant to cut tubulars with increased chrome amounts, as well as alloying elements such as nickel, vanadium, molybdenum, titanium, silicium. This method is also applicable to cutting in environments with water, salt water, and drilling fluids.
[0051] A cover 55 may be provided with an embodiment of the cutting tool 52 D for retaining grease within the tool 52 D. Shown in perspective view in FIG. 13 , the cover 55 envelops a portion of the cavity 63 where the blade 58 is deployed. The cavity 63 can be packed with grease prior to being deployed and the cover 55 put in place thereby retaining the grease in the cavity 63 and on the blade 58 while the tool 52 D is being lowered downhole. The cover 55 is shown hinged on an end to the housing 54 D so that it can swing open and not impede the blade 58 as it is pivoted radially outward. Selectively opening the cover 55 during cutting enables grease to also migrate to the cutting surface. The cover 55 may be biased, such as with a spring or like member, so that it follows the blade 58 and closes over the cavity 63 as the blade 58 is re-stowed within the housing 54 D).
[0052] In an optional embodiment shown in FIGS. 14A-15B , grease and/or lubricant from a reservoir on one side of the cutting blade 58 can be dispensed to an opposite side of the blade 58 . Shown in a partial sectional perspective in FIG. 14A , a section of the nose portion 62 E of the cutting tool 52 E projects past the cutting blade 58 having an end terminating at a blade mount 93 . The blade mount 93 shown houses a portion of a shaft 94 for rotating the cutting blade 58 and gears for driving the shaft 94 . A pivot shaft 95 couples within the blade mount 93 , that when rotated pivots the blade mount 93 and blade 58 . In the cutting tool 52 E example of FIGS. 14A-14C , when the tool 52 E is being deployed and the cutting blade 58 is stowed, the sealing plug 77 E end opposite the spring 73 is urged against the fastener 60 by the spring 73 . Grease and/or lubricant may be introduced into the reservoir 76 E via an inlet port 83 disposed in a lateral bore 85 formed radially inward into the nose portion 62 E. An axial bore 87 intersects the lateral bore 85 to communicate grease and/or lubricant injected into the port 83 to the reservoir 76 E. The lateral bore 85 as shown intersects the passage 71 E.
[0053] A channel 81 is provided on the blade mount 93 on a side of the cutting blade 58 opposite the reservoir 76 E ( FIG. 14B ). The channel 81 registers with the passage 71 E discharge side and extends along the blade mount 93 . The other end of the channel 81 terminates between the blade 58 outer periphery and mid section in communication with the side of the blade 58 opposite the reservoir 76 E. Thus lubricant and/or grease can be dispensed onto the cutting blade 58 by flowing it from reservoir 76 E, into the passage 71 E, and through the channel 81 . FIG. 14C provides a sectional view of the cutting tool 52 E taken along its axis on the reservoir 76 C side of the cutting blade 58 . The section of the nose portion 62 E extending past the blade 58 has a width that tapers along its circumference thereby forming a crescent shape. The wider section of the nose portion 62 E is disposed proximate and perpendicular to the pivot shaft 95 . The wider section also includes the passage 71 E discharge; thus as shown, the passage 71 E discharge is proximate to the pivot shaft 95 .
[0054] FIGS. 15A and 15B provide side and axial sectional views of the cutting tool 52 E in a cutting position. The section of the nose portion 62 E extending past the blade 58 encircles less than half the blade 58 ; this leaves an open space allowing the blade 58 to pivot radially outward into cutting contact with a tubular. Because the passage 71 E discharge is aligned with the pivot shaft 95 , the passage 71 E remains registered with the channel 81 while the blade mount 93 and blade 58 are being pivoted into cutting contact. Thus as the blade 58 spins during a cutting procedure, grease and/or lubricant can be deposited on its side and delivered to the cutting surfaces such as by the centrifugal force of the blade 58 .
[0055] The improvements described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While presently preferred embodiments have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims. | The tubular cutting tool for severing downhole tubulars, the tool having a drive system, a pivoting system, a cutting head, a cutting member, and a lubricant delivery system. Cutting may be accomplished by rotatingly actuating the cutting head with an associated motor and extending the cutting member away from the cutting head. The lubricant delivery system lubricates the respective contacting surfaces of the cutting member and the tubular and is actuated when the cutting member extends from the cutting head. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/481,232, filed Aug. 14, 2003, which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to communications, more particularly, to customer premises-based telephone systems.
BACKGROUND OF THE INVENTION
Phone systems for businesses have typically provided a higher level of functionality than basic telephone service, providing functions such as blind call transfer, attended call transfer, line and set availability indication, to name but a few. This functionality has classically been provided by some type of central control, most commonly a Private Branch Exchange (PBX) or more recently “telephone server”.
The central control systems have drawbacks in terms of high initial cost, single point of failure and complexity in setup and administration. The initial cost of the central control point was particularly prohibitive to small businesses that only needed a few telephones.
To address these limitations some phone systems have been developed that don't have a central control. An example of a telephone system without a central control point is U.S. Pat. No. 4,757,496, titled “Distributed Telephone System”, which describes a telephone system where each Telephone Set is coupled to a common coaxial cable. Unfortunately, this system still requires either a fixed administration, or manual programming, to set some system parameters such as Telephone Set addresses. More importantly it was limited in that the phones had to be geographically located relatively close together.
U.S. Pat. No. 6,256,319, titled “Plug and Play Telephone System” also describes a telephone system without a central control point. It describes a system where each Telephone Set is connected to every other Telephone Sets by a common telephone line connection. Across this common telephone line connection a radio frequency (RF) based communication channel is created. Unfortunately, this RF communication channel method imposes numerous limitations on the telephone system operation. Notably, these include:
limits to the number of telephone sets that can share the common telephone line connection because of regulatory limitations on “ringer equivalence number” (REN) loading factors. This factor limits how large the telephone system can become, typically up to only 12 telephone sets. the RF communication channel method is limited by telephone line lengths, terminations and interference with common DSL services. This factor limits the reliability and performance of the system in real-world deployments. the RF communication channel method only allows the telephone system to operate from a single user premise. This factor prevents the system from operating across a geographically distributed area. the RF communication channel method only allows a limited number of simultaneous full-duplex audio paths across the communication channel. This factor limits system functionality and size, because users and/or features are blocked when all of the full-duplex audio paths are in use. The more users in a system, the greater the likelihood that blocking would occur. the RF communication channel method, as commonly implemented, requires that multiple analog phone lines are cabled to each phone location. This factor increases the cost and complexity of wiring up the phone system in real-world deployments.
With the advent of Voice-over-data or Voice-over-Internet-Protocol (VOIP), business oriented telephone systems have been created that use VOIP telephone sets and VOIP aware central point of control commonly called an “IP PBX” or simply “telephone server”. This central control point provided functionality similar to classical PBXs and had the same drawbacks of single point of failure and high initial cost relative to deployments of small numbers of phone sets.
While individual VOIP phones could call each other without the use of a IP PBX, this is more analogous to basic telephone service without such features as set-availability or line-in-use indicators.
SUMMARY OF THE INVENTION
A VoIP phone apparatus is provided that comprises an Foreign Exchange Office (FXO) circuit attachable to an external Plain Old Telephone Service (POTS) line and operatively connected to a Telephony Control IC and a Microcontroller, the FXO circuit providing Ringing and Status signals to the Telephony Control IC and generalized FXO-RX and FXO-TX signals to an Analog Audio Switch Matrix subcomponent of the Telephony Control IC. The apparatus also has at least one Audio Transducer set comprising at least one microphone and at least one speaker operatively connected to the included Analog Audio Switch Matrix subcomponent of the Telephony Control IC. Further it has the Microcontroller operatively connected to a keypad, a Computing Processor, an electrical power source, and the Telephony Control IC, for providing and receiving control and state signals to and from the Telephony Control IC. The phone apparatus also has at least two A-D converter sets operatively connected to the Computing Processor for dealing with digitized audio signal I/O with said Computing Processor, providing matching analog signal I/O over two signal sets: with the Telephony Control IC. The Computing Processor is equipped with a Memory Subsystem and Computer Networks interface capable of communication with a Local Area Network (LAN) or a Wide Area Network (WAN), if connected, and a user interface comprising a display, input device and indicators.
Also provided is a server-less VoIP system comprising at least two telephone sets connected on a network, where each of said telephone sets is comprised of at least computer processing, memory, Computer Network interface, and audio processing. Each telephone set has its own system and call-processing software and communicates via its Computer Network interface with other devices on the network using IP or similar un-switching communications protocols across a LAN or WAN network using IP or similar packet-switching protocols.
A method of operating a server-less phone system is provided where a call is received by one VoIP phone in a server-less system. The incoming call can be either a VoIP call or an FXO call. The phone that has received the call can then invite multiple other phones simultaneously by sending each a message such as the Session Initiation Protocol (SIP) INVITE message. This has the effect that said multiple phones all ring or otherwise behave as each is configured to behave. The first phone or device to respond to the initiating phone with a SIP OK message will have the call routed to it. The call requests to the other remaining phones will be cancelled. How the call is routed to the responding phone varies with the type of the original call. If it was a call originating on the FXO lines, the call is gatewayed to the responding phone. If the call originating as a SIP call, it can be transferred to the responding phone.
The VoIP phone apparatus also provides a means of being able to both make and receive FXO calls when main power is unavailable. The apparatus makes use of power from the phone network when externally supplied electrical power fails. To do this the phone includes a sensing and switching means which provides power for the system from the externally supplied electrical power when that source is available, but when the sensing means senses that only phone-line power is available it switches power off to parts of the system including the Computing Processor with its associated A-D converter sets, memory subsystem, Computer Network interface, display and indicators. It then directs available power to the Telephony Control IC and other associated subcomponents of the system, thus “failing over” to become a minimal POTS telephone set when externally supplied electrical power is unavailable but power from the phone network is available.
The VoIP Phone apparatus provides a means for the user to selectively control the recording of audio on the phone. The user can begin and end recording either through a key on the user interface or based upon a configuration file. The configuration file could, for example, define that all calls from or to a particular number always be recorded. The audio selected to be recorded is digitized and is either saved internal to the phone in its memory for later retrieval or first saved then moved external to the phone, typically in the form of an audio file attachment to an email or series of emails. When the recording size exceeds the capacity of the phone's memory, the recording can emailed or otherwise moved external to the phone over the network, in increments as the recording reaches certain intervals or size. The recording of audio can be done both while the phone is not otherwise in use and while any type of call is in progress including an FXO call, a VoIP call, or a conference call.
A method of using the VoIP phone apparatus is provided whereby a user at another VoIP phone connected to the apparatus via a LAN or WAN can monitor a call on the apparatus without one or more parties to the call being aware of such monitoring. Similarly a method is provided whereby the audio mixing capabilities of the phone are used so the monitoring party on the call can speak to the user of the apparatus without the other parties to the call being able to hear what is spoken by this monitoring person.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of an illustrative Telephone System 100 ;
FIG. 2 shows a functional-level block diagram of an illustrative Telephone Set 200 device;
FIG. 3 shows a block diagram of an illustrative Telephone System 700 ;
FIG. 4 shows a functional-level block diagram of a Voice Messaging 500 device;
FIG. 5 shows a functional-level block diagram of a Multi-Port FXO Port 800 device;
FIG. 6 shows a functional-level block diagram of a Ti/El Access 400 device;
FIG. 7 shows a functional-level block diagram of Multi-Handset Cordless 600 devices;
FIG. 8 shows an illustrative method for a typical device initialization and discovery sequences;
FIG. 9 shows a illustrative block diagram of a the call recording mechanism of Telephone Set 200 ;
FIG. 10 shows a illustrative block diagram of a the call monitoring mechanism of Telephone Set 200 ;
FIG. 11 shows a illustrative block diagram of a the voice (non-call) recording mechanism of Telephone Set 200 ;
DETAILED DESCRIPTION
General Overview
A preferred embodiment of the Server-less VoIP Telephone System invention is illustrated in FIG. 1 . Telephone System 100 is comprised of one or more Telephone Set 2 - 1 through to 2 -N. Each Telephone Set can optionally be connected to a unique Analog Telephone Line 1 - 1 through to 1 -N. The Analog Telephone Line is a loop-start wire pair representative of facilities provided by a local central office or PBX (not shown), and is known in the art.
Each Telephone Set 2 - 1 through to 2 -N is connected to a LAN/WAN Network 6 via LAN Connections 3 - 1 through to 3 -N. For the purposes of this description, each LAN Connection is assumed to be a commodity 10/100 Mbps WEE 802.3 Ethernet LAN cable connection. However, the LAN/Connection can also be made other ways, such as by Bluetooth™, 802.11 or other wireless means, routing IP traffic over other connections such as Firewire™ or USB™. This invention is not to be limited by the style of mechanical LAN Connector described, which is merely exemplary of the current preferred embodiment. The LAN/WAN Network 6 operates using industry-standard Transmission Control Protocol/Internet Protocol (TCP/IP) networking protocols. This LAN/WAN Network 6 consists of local area network(s) (LAN) and/or wide area network(s) (WAN).
This LAN/WAN Network 6 can be comprised of any one or more of the following items: local Ethernet switches, hubs, routers, firewalls, network address translators (NAT), intranets, public Internet, private TCP/IP WAN networks, or any other related network devices and implementations.
The purpose of the LAN/WAN Network 6 is to provide a local and/or wide area switching network for transport of digitized voice and control data to/from the Telephone Set, in addition to providing a communication medium for other common industry TCP/IP devices (PCs, printers, servers, Internet, other devices and networks). These TCP/IP network elements, and the mechanisms behind their operation, are well known to one skilled in the art, and will not be described further.
With just these elements alone, a full-featured telephone system is created. It supports all common calling modes found in a conventional phone system, such as external PSTN calls and internal business intercom calls. Unlike the prior art, the phone system can also handle voice-over-Internet-protocol (VoIP) calls across a wide area network (WAN).
This simple Telephone System 100 can also provide desirable voice messaging features such as auto-attendant and voicemail functionality. And unlike any other prior art, the Telephone System 100 can provide a method for advanced voice messaging features, whereby voice mail messages, call recordings, and/or voice recordings messages are handled by the Telephone Set alone, and can be delivered to end users or services via common TCP/IP delivery techniques such as e-mail.
The methods behind the delivery of these features will be described later in this description.
Telephone Set Description
The telephone set is the inventive apparatus for the Telephone System 100 . For the purposes of this description, each Telephone Set 2 - 1 through to 2 -N is assumed to be identical in terms of design. As such, only one illustrative telephone set, Telephone Set— 200 is described in detail below. An illustrative functional block diagram of a portion of Telephone Set 200 , which embodies the principles of the invention, is shown in FIG. 2 . The following describes pertinent design details and the function of each element referenced in— FIG. 2 .
FXO Circuit 10 ; This circuit provides the functionality of a FXO circuit familiar to one skilled in the art. This includes on and off hook switch control. There is a 2 to 4 wire hybrid audio circuit interfacing the 2 wire telephone line 89 loop start signal pair to the (4 wire) transmit and receive audio signals FXO_TX and FXO_RX respectively.
The STATUS signal provides such status information as FXO line voltage and/or current indications. Analog audio signals FXO_RX and FXO_TX and STATUS, and the ringing voltage signal (RINGING) signal is connected to the Telephone Control IC 13 .
It is also noted that the FXO Circuit 10 provides the Telephone Set 200 ground signal reference. This ground signal reference is accomplished with a common diode bridge following the 2 wire telephone line 89 TIP and RING leads. Ground is effectively referenced to the most negative voltage of the telephone line.
Audio Transducers 12 ; These audio transducers represent the common handset audio and speakerphone transducers. Their design and interconnection are familiar to one skilled in the art. For the handset, the analog audio signals are HS_IN and HS_OUT. For the speakerphone transducers, the analog audio signals are HF_MIC and HF_SPKR.
Telephony Control IC 13 ; This integrated circuit (IC) provides a non-blocking analog audio switch matrix between the following analog audio inputs: FXO-RX, HS-IN, HF-MIC, AIN1, AIN2 and DTMF/TONE (internal) and the following analog audio outputs: FXO-TX, HS-OUT, HF-SPKR, AOUT1, AOUT2. The internal audio generator DTMFPTONE is able to generate Dial-Tone Multi-Frequency (DTMF) and simple tone audio signals.
A key feature of the Telephony Control IC 13 is that it can generate power, herein after referred to as “VCC” power, when the main 5V power is not present. This VCC power is derived from the FXO line current when off-hook, or from the FXO ringing signal when on-hook. Only the Telephony Control IC 13 , the Microcontroller 11 , the FXO Circuit 10 and the Audio Transducers 12 are powered with VCC.
The Telephony Control IC 13 is controlled, and can provide status information to the Microcontroller 11 via the CTL_DATA signals.
5V Power Blocking Diode 74 ; This diode provides isolation between the 5V and VCC DC power signals. As mentioned in describing the Telephony Control IC 13 , if the 5V DC power signal is not present, this diode will prevent any VCC DC power generated by the Telephony Control IC 13 from feeding into the 5V power rail. It is, of course, understood that other voltages may be used in different embodiments of this invention without taking away from the invention disclosed here.
5V Power Comparator 75 ; This is a simple voltage comparator circuit that compares the VCC and 5V voltage levels. If the 5V signal is present, a logic 1 POWERFAIL-signal is presented to the Microcontroller 11 , otherwise a logic 0 POWERFAIL-signal is presented. To prevent electrical latchup of the VCC powered devices from the other non-powered devices in the apparatus, the Microcontroller 11 uses this signal to know when to electrically isolate the UART signal. The AOUT1 and AOUT2 signals are capacitive-coupled to the Dual A-D Converters 78 , so they already would have DC isolation between the VCC powered Telephone Control IC 13 and the non-VCC powered Dual A-D Converters 78 . The design of this comparator is well known to one skilled in the art.
Microcontroller 11 ; The Microcontroller 11 is powered via the VCC DC power signal, which is derived via the main 5V power rail, or in the absence of such, via VCC generated by the Telephony Control IC 13 . This microcontroller requires a low operating current (typically <8 mA). This limit is because the Telephony Control IC 13 is limited in how much power (current) it can deliver to VCC when the main 5V power rail is absent.
Via the CTL DATA and HOOK-CTL signals, the Microcontroller 11 can control the operation of the FXO Circuit 10 and the Telephony Control IC 13 . The Microcontroller 11 has a standard 2-wire UART connection to the Computing Processor 14 , whose purpose is to communicate messages between each other.
The Microcontroller 11 also performs key press detection on the Keypad Scanning Matrix 79 , as is familiar to one skilled in the art.
The control firmware resident in this Microcontroller 11 operates in 2 modes. When it detects lack of 5V power via the 5V Power Comparator 75 , the Microcontroller 11 operates in Autonomous mode. In Autonomous mode, the Microcontroller 11 fully controls the FXO Circuit 10 and the Telephony Control IC 13 . This allows the Telephone Set 200 to operate similar to a plain analog POTS telephone.
When it detects the presence of 5V power via the 5V Power Comparator 75 , the Microcontroller 11 operates in Slave mode. In Slave mode, the Microcontroller 11 reports status information (key presses, ringing signals, etc.) using UART messages to the Computing Processor 14 . The FXO Circuit 10 and the Telephony Control IC 13 are only controlled by the Microcontroller 11 upon reception of the appropriate UART message(s) from the Computing Processor 14 .
The design of the microcontroller firmware supporting Autonomous and Slave modes is familiar to one skilled in the art.
To one skilled in the art, they can now see how the Telephone Set 200 can operate without the main 5V power rail, and act as a regular POTS line-powered telephone. Advantageously compared to the prior art, one can see that the inventive Telephone System 100 can provide power fail operation to each of the unique Analog Telephone Line 1 - 1 - through to 1 -N connected to Telephone Sets 2 - 1 through to 2 -N.
For the duration of this patent description, it is described such that it is assumed that the Telephone Set 200 is operating under normal 5V powered conditions.
Keypad Scanning Matrix 79 ; This is a standard row/column keypad scan matrix that is familiar to one skilled in the art. It is operated by the Microcontroller 11 , and its purpose is to detect when keys are pressed and released.
System Power Conversion 76 ; The System Power Conversion 76 provides various DC voltage rails as needed by the Telephone Set 200 . For the purposes of this description, 5V is a required voltage rail. Other DC rails are provided as needed by any specific design. The INPUT POWER is any AC or DC input power signal that is appropriate for the design. It could be delivered via a wall power cube, or delivered through wires on the LAN cable (e.g. as defined by IEEE 802.3af standard). Both of these methods are known by one skilled in the art, and other methods are of course also obvious.
Since the description of this design indicates that Telephone Set 200 ground signal is referenced to the telephone line, INPUT POWER must have appropriate safety/regulatory voltage isolation from the telephone line, as is familiar to one skilled in the art. Alternatively, one skilled in the art can devise alternative electrical designs whereby the FXO Circuit 10 provides the necessary safety/regulatory voltage isolation, and yet still provide power fail operation.
Dual A-D Converters 78 ; The Dual A-D Converters 78 provide 2 channels of analog-digital and digital-analog conversion paths to the analog audio signals AIN1, AIN2, AOUT1, AOUT2 emanating from the Telephony Control IC 13 . The digitized signals are transported to/from the Computing Processor 14 via a multiplexed digital data stream, such as a PCM stream bus, familiar to one skilled in the art.
Computing Processor 14 ; This element represents the digital control processor unit for execution of the main apparatus application firmware. It can consist of appropriate microprocessor and/or DSP processing devices as is required, and known by one skilled in the art. The Computing Processor 14 runs the application software resident in the Memory Subsystem 17 . When 5V (or as otherwise appropriate) power from the main power rail is present, the Computing Processor 14 controls the whole operation of the Telephone Set 200 .
A key element is that the Computing Processor 20 requires sufficient computing power and appropriate software algorithms to process these audio signals. These capabilities include the following:-flexible audio frequency band tone (and multi-tone) generation and detection capabilities. This is used for such items as DTMF tone detection and generation, caller-id (and call-waiting id), Frequency Shift Keying (FSK) signal detection, and various other common telephony tone signaling activities:
when audio to/from the FXO and/or speakerphone transducers is transported across the LAN Interface 15 , algorithms are required to perform appropriate line and/or acoustic echo cancellation within Telephone Set 200 . The design parameters around these echo cancellers are well known, and are their performance criteria is well described in the International Telecommunications Union (ITU) G.168 standard. ability to handle multiple independent instances of playing and recording audio data from/to the Memory Subsystem 17 . flexible audio gain control is required for all audio paths. This would include audio muting and automatic gain control circuits as needed. flexible audio mixing, and if desired, audio conferencing control of various audio output and input paths. The audio mixing capabilities facilitate call recording and call monitoring capabilities. The mixing/conferencing with audio paths to/from the Telephony Control IC 13 analog audio switch matrix, and one or more call sources to/from the LAN network.
Memory Subsystem 17 ; This element provides all of the volatile and nonvolatile memory storage for the application software, data and algorithms, as required for any devices as part of the Computing Processor 14 . Examples of this memory storage are flash memory, SDRAM memory, EEROM and are well known to one skilled in the art. The application software and algorithms contain all the functions to perform the necessary TCP/IP and VoIP protocol stacks such as TCP, User Datagram Protocol (UDP), Real-time Transport Protocol (RTP), SIP, Simple Mail Transport Protocol (SMTP), Hypertext Transfer Protocol (HTTP), File Transfer Protocol (FTP), and Trivial File Transfer Protocol (TFTP).
LAN Interface 15 ; This element provides the Ethernet 802.3 interface, which includes the media access controller (MAC) and physical interface (PHY).
Display and Indicators 16 ; This element represents common telephone items such as indicator LEDs, LCD display, buttons. The interconnections of such are well known to one skilled in the art.
Telephone Set 200 Suggested Off-the-Shelf Integrated Circuits
The key elements of Telephone Set 200 can be build by using “off-the-shelf” integrated circuits. To aid one skilled in the art to rapidly be able to put in place most of these key elements, one could recommend the following commercial integrated circuits:
Broadcom™ BCM1101 VoIP Processor. This IC effectively provides the functionality of the Computing Processor 14 , Dual A-D Converters 78 and LAN Interface 15 . It typically is also sold with many of the requisite microprocessor and DSP software protocols and algorithms required.
Atmel™ U3900BM Telephony Processor. This IC effectively provides functionality of the FXO Circuit 10 and Telephone Control IC 13 .
Atmel™ AT90S8515 AVR Microcontroller. This IC effectively provides functionality of the Microcontroller 11 and 5V Power Comparator 75 .
Manufacturer datasheets and application notes relating to the above integrated circuits give an abundance of information of technical information as to the operation and recommended design considerations to allow one skilled in the art to be able to replicate many of the key elements of Telephone Set 200 .
VoIP Protocols Operational Description
For the purposes of this patent description, we will describe the VoIP protocol functionalities of the Telephone System 100 and Telephone Set 200 with respect to the usage of the SIP and RTP protocols. For example, it is well understood by one skilled in the art that digitized audio data is transported across the LAN Interface via the RTP protocol, and call setup and control information is transported across the LAN Interface 15 via the SIP protocol. The IETF reference document that explains the SIP and RTP protocols can be found in RFC 3261 and RFC 3550 respectively.
The following is an illustrative example, with regards to VoIP protocol operation of the Telephone Set 200 .
When the incoming Public Switched Telephone Network (PSTN) call arrives at the telephone line, it generates a ringing signal. Via the FXO Circuit 10 and the Telephony Control IC 12 , the Microcontroller- 11 is notified that the line is ringing, and if available, would be notified of any caller identification information. It relays this status information to the Computing Processor 14 via a UART message.
The Computing Processor 14 can now initiate a SIP call to one or more other Telephone Set 200 devices (including itself on the LAN/WAN Network 6 by sending out the appropriate SIP INVITE messages to the other Telephone Set 200 devices. If the Computing Processor 14 receives a SIP OK message from a Telephone Set 200 via the LAN/WAN Network 6 , it can proceed to set up the call by sending message(s) to the Microcontroller 11 to take the FXO Circuit 10 to an off-hook state, and to route the FXO_RX and FXO_TX audio signals through the Telephony Control IC switch matrix to the AIN1 and AOUT1 audio paths. This connected audio can pass through one channel of the Dual A-D Converters 86 and the digitized audio is transported via the LAN Interface 15 via the RTP protocol to the other Telephone Set 200 on the LAN/WAN Network 6 . Now a complete call path is in session between the FXO Circuit 10 , and another Telephone Set 200 on the LAN/WAN Network 6 .
At the same time, an appropriate SIP INVITE message can be received at the same Telephone Set 200 via the LAN Interface 15 . The Computing Processor 14 can send a message via the UART to Microcontroller 11 to alert the human user of Telephone Set 200 via an audible alerting signal that an incoming call from another Telephone Set 200 is available. The Microcontroller 11 can detect when the user picks up the handset (or activates a speakerphone key press), and send this status information via the UART to the Computing Processor 14 . The Computing Processor 14 can now send a SIP OK message to the calling Telephone Set 200 on the LAN/WAN Network 6 .
The Computing Processor 14 proceeds to send message(s) to the Microcontroller 11 to route the appropriate Audio Transducers 12 audio signals through the Telephony Control IC switch matrix to the AIN2 and AOUT2 audio paths. This connected audio can pass through the second channel of the Dual A-D Converters 86 and the digitized audio is transported via the LAN Interface 15 via the RTP protocol to the other Telephone Set 200 on the LAN/WAN Network 6 . Now a complete call path is in session between the human user, and another Telephone Set 200 on the LAN/WAN Network 6 .
It is important to note that the call from the FXO Circuit 10 , and the call answered by the human user are independent of each other. That is, the Telephone Set 200 can simultaneously perform an independent SIP call session on the FXO Circuit 10 , and another independent SIP call session using the Audio Transducers 12 . This is not the case with the prior art of VoIP phones that contained a FXO port.
To one skilled in the art, it is apparent how outgoing and incoming FXO calls can occur, or how a human user could also initiate and receive a call, and how these calls would be terminated. It is also possible for the incoming FXO call to have been answered by a human user on the same Telephone Set 200 device.
Server-Less VoIP Telephone System Operation
In a preferred embodiment the inventive VoIP Telephone System 100 , each Telephone Set 200 communicates, via its LAN Interface 15 , to other devices using peer-to-peer TCP/IP communication protocols. Each LAN connection 3 - 1 through 3 -N for each Telephone Set 200 device could be on different LAN or WAN segments, different TCP/IP networking equipment, and finally, located across both small and large geographical distances. Unlike the prior art using the RF communication method, this communication path is not along a common, shared RF communication path, but rather across distributed and network addressable path, the LAN/WAN Network 6 .
This has the major advantage over prior art RF communication methods, for it overcomes the aforementioned disadvantages of RF channel capacity, line REN limits, and shared telephone line cable lengths and terminations. In addition, when a power fail situation occurs, each Telephone Set 200 device can provide basic ability to make and receive phone calls on any unique analog loop-start lines routed to the FXO port of such Telephone Set— 200 . This is unlike prior art where power fail operation was limited to only the one shared loop-start line, or relied on the usage of additional regular POTS phones connected on the analog loop-start lines. This provides numerous end user safety and convenience advantages for a business experiencing a power fail or LAN outage.
Another key advantage is that Telephone Set 200 devices could be deployed across a potentially very large geographical distance via the LAN/WAN Network 6 , limited only by the capability of the WAN. For example an office could have several Telephone Set— 200 devices on their customer premises, and other Telephone Set 200 devices located in different towns, cities and even countries. This is a capability not found in the prior art.
In accordance with the principles of the invention, the elements shown in FIG. 1 , i.e., Telephone Sets 2 - 1 to 2 -N communicate to each other over the LAN/WAN Network 6 in a peer-to-peer manner. In other words, there is no centralized server coordinating the actions of each telephone set. Each Telephone Set 200 comprises its own system and call processing software. As described further below, Telephone System 100 is self-configurable. The system accomplishes this by allowing each Telephone Set 200 to supply specific information and capabilities about themselves to other Telephone Set 200 devices upon request.
In addition, each Telephone Set 200 can subscribe to receive notifications of changes in resource status of other Telephone Set 200 devices in the system. As a result, Telephone System 100 provides plug-and-play functionality. Examples of system resources are: intercom number, voice channels, FXO line capabilities, voice messaging services, etc. Examples of changes in resource status include whether not a FXO port(s) is presently in use, whether a user is actively using a Telephone Set device, information on various intermediate states of a resource (e.g. ringing, on-hold, idle, do-not-disturb, and similar reports).
Upon initialization, each Telephone Set 200 goes through various discovery stages about the telephone system available on the LAN/WAN environment. The end result of these stages is that the system is capable of discovering other Telephone Set 200 devices, and gathers enough information from those devices to be able to self-organize into an operating VoIP telephone system. This includes auto-assignments of intercom extension numbers, knowledge of available external analog loop-start lines, availability of system voice messaging features. During this stage, it may prompt the user for further information depending on how successful it was in determining its external environment.
For illustrative purposes, FIG. 8 shows the various stages involved. Below describes one implementation of these discovery stages. Various alternative methodologies would be obvious to one skilled in the art. For illustrative purposes only, description of these stages refers to commonly defined usage of the Internet and SIP protocols.
The first stage 300 is called Device Address. The first action of the Telephone Set 200 is to determine an IP address for itself. By default the Telephone Set 200 uses Dynamic Host Configuration Protocol (DHCP) to obtain a dynamically assigned IP address from a DHCP server on the LAN network. Alternatively, the telephone set could be configured a static IP address, as is common for VoIP telephone sets. All other basic telephone set initializations occurs during this stage.
The second stage 305 is called Device Discovery. Using common broadcast, unicast and/or multicast techniques familiar to one skilled in the art, the Telephone Set 200 attempts to determine whether or not it is in a different LAN network. If it is in a different LAN network environment from when it was last powered, or LAN cable was unplugged and reinserted, or if it is the first time the Telephone Set 200 has ever been initialized, the Telephone Set 200 will attempt to discover the basic presence of other like Telephone Set— 200 devices on its local LAN environment.
For illustrative purposes only, this discovery can occur by the initializing Telephone Set 200 sending out a broadcast SIP OPTIONS message to its local LAN segment. A broadcast message is illustrated only because many small business establishments typically have low-end routers that may not support multicast, or require special network administration skills. It can also send unicast or multicast SIP OPTIONS messages to devices on the WAN. Familiar to one skilled in the art, recipients of the SIP OPTIONS message will send back a message indicating information and capabilities of the recipient device. This allows the Telephone Set 200 to, first of all, know what devices are on the network, and secondly, determine the capabilities of the responding Telephone Set 200 devices. The initializing Telephone Set 200 can then make a decision as whether or not this capability is of interest. As the state of the art changes, alternative discovery protocols such as uPnP and zeroconf may become appropriate alternative discovery methods and this invention is thus not limited to SIP.
This stage is also important for any responding Telephone Set 200 , for it is now aware that the initializing Telephone Set 200 is present on the network. For example, it is common for the reply message to have a “User-Agent” field. This field could indicate that the device represents a Telephone Set 200 , and possibly have extra specific information about the device. This is for illustration purposes only, for the device discovery methods using SIP protocols are still in flux.
Pertinent information about this stage 305 is stored locally in non-volatile memory storage area on the Telephone Set 200 . This system information includes, at a minimum, what Telephone Set 200 devices types were discovered, their IP addresses, and for Telephone Set 200 devices, their assigned intercom number.
If the Telephone Set 200 determines that it is in a different LAN network, then the Telephone Set 200 reconfirms and updates the system information that is stored in the Telephone Set 200 non-volatile memory storage area (data store). Any newly discovered Telephone Set 200 devices are added to the data store. Any devices no longer present on the system are typically removed from the data store. The user may optionally be prompted to confirm this action. In certain situations their information may be delayed in removal by an appropriate aging algorithm. This is to prevent inadvertent re-assignment of intercom numbers if another previously discovered Telephone Set 200 device is off-line (not present) in the system for a short duration. This duration might typically be 15 days or less, or this duration could be determined by an administrative setting.
System information as described above is discovered automatically. This system information can be augmented by fixed information entered into the Telephone Set— 200 via a local or remote administration service. This allows the inventive phone system to accommodate devices that cannot be located by the System Discover stage, and to support third-party VoIP devices or services. These administrative methods are known to those skilled in the art. They would include administration settings accessed with the telephone set keypad and LCD display, or by processing appropriate messages received on the LAN Interface 15 , or by any other known programming interface.
The next stage 310 is called Device Registration. In this stage, the Telephone Set 200 attempts to register itself to each of the other Telephone Set 200 devices in the system, using the SIP REGISTER method. The other Telephone Set 200 devices can either accept or reject this registration attempt. If a Telephone Set 200 rejects a registration attempt, it just means that our Telephone Set 200 cannot take advantage of the resources or services of the rejecting Telephone Set 200 .
If it is of interest, the Telephone Set 200 has the option, now, or at a later time, to go to the stage 315 , called Device Subscribe. Using the SIP SUBSCRIBE method, the Telephone Set 200 can subscribe to one or more asynchronous event notifications from other Telephone Set 200 devices available on the network. The subscribed Telephone Set— 200 delivers these to the subscriber via the SIP NOTIFY method.
The SUBSCRIBE and NOTIFY are important mechanisms to allow a Telephone Set 200 to receive notification from another Telephone Set 200 indicating pertinent status information such as FXO port being in use, if the set is in use by a human user, or do not disturb settings. This allows the Telephone System 100 as a whole to deliver common expected features such as FXO line and set indicators. Again, this information is delivered to each Telephone Set 200 from an individual Telephone Set 200 and not coordinated by a central control server. The IETF reference document that explains these SIP methods can be found in RFC 3265.
Beyond stage 315 , the Telephone Set 200 moves to stage 320 , called the Device Ready state. Here the Telephone Set 200 is ready to operate and participate in the system. It is noted that other Telephone Set 200 devices may do the same stages 305 , 310 and 315 against this Telephone Set 200 , such that they can take advantage of the resources and capabilities of the newly initialized Telephone Set 200 .
From the Telephone Set 200 perspective, it is now aware of other Telephone Set 200 devices on the network. It is also aware of the availability of FXO port(s), if any, on the network. To make use of these system resources, the Telephone Set 200 would make use of various SIP messages such as INVITE, OPTIONS, SUBSCRIBE and NOTIFY messages to know the status and/or current capabilities of the specific system resource, and request the usage of that system resource. Calls to/from the Telephone Set 200 can occur using known SIP INVITE methods. The Telephone Set 200 device can handle independent SIP sessions for use of its FXO port(s), if available, and also for the use of the device transducers. Using SIP messaging, the ability of a system resource to accept or reject a SIP request method are known to one skilled in the art.
To stay aware of any dynamic changes in the network, and hence the phone system, the Telephone Set 200 periodically repeats Stage 305 to determine if there are changes in the Telephone System 100 . (i.e. Telephone Set 200 devices added, removed, changed). It is suggested that this Stage 305 is repeated at intervals of 2 minutes or less to be responsive to the changes.
In the inventive Telephone System 100 , a Telephone Set 200 require the capability of performing a technique called SIP INVITE parallel forking, referred subsequently as forking, and is known to one familiar with the art. This is a feature commonly available from a TCP/IP protocol telephone system with a centrally control server. Within this central server, this forking capability is commonly provided by what is called a proxy server software component.
But since a centrally control server is not part of the inventive system, the Telephone Set 200 devices themselves require this capability. Forking is a key requirement to handle typical multi-line phone system scenarios. SIP INVITE messages are the foundation for establishing a VoIP communication session with another device. Recipient devices will either accept (SIP OK response) or reject (SIP non-OK response) the INVITE. If a device wants to, it can INVITE multiple devices to a session at the same time. This is forking, and the device typically accepts the first device that responds with an OK response, and cancel (SIP CANCEL and/or BYE messages) to any of the other responding devices.
For illustrative purposes, the following is a description of one instance where forking is required. When a Telephone Set 200 device receives an incoming call on its FXO port, it will generally want to alert (ring), all other Telephone Set 200 devices in the system. It does this by forking (sending SIP INVITE message) to all the Telephone Set 200 devices. The Telephone Set 200 handles the forking process, and will route the FXO voice call to the first Telephone Set 200 device that responds with an OK response. By default, all of the Telephone Set 200 devices in the system would be forked to, but it could be a subset of this, depending on various user-defined parameters such as caller-id information, time/date, and Telephone Set states.
Another illustrative example of where forking is required is for when an external SIP call originates from the WAN. The WAN device that originated the call generally may not know the specific IP address of a Telephone Set 200 because of NAT/Firewall (router) issues. The incoming SIP call would be “port forwarded” by the router to a Telephone Set 200 that is designated to act as recipient for external WAN SIP calls. When the designated Telephone Set 200 device receives an incoming SIP call on its LAN Interface 15 , it will resolve the SIP URI to determine the actual intended Telephone Set 200 device(s). It will generally want to alert (ring), all other Telephone Set 200 devices in the system. It does this by forking (sending SIP INVITE message) to all (or a subset of) the Telephone Set 200 devices. The designated Telephone Set 200 handles the forking process, and will route the WAN SIP call to the first Telephone Set 200 device that responds with an OK response. This forking process is familiar to one skilled in the art.
Each Telephone Set 200 device in the system needs to share and maintain appropriate common system data current amongst all of the Telephone Set 200 devices. In the spirit of the inventive system, the devices would co-operatively share this information amongst themselves by sending/receiving messages across the LAN/WAN Network 6 . Many methods to do this are familiar to one skilled in the art. Naturally one needs to take necessary steps to ensure the validity and integrity of this shared data.
It should be noted that the inventive Telephone System 100 provides non-blocking operation of intercom calls between Telephone Set 200 devices. This means that any Telephone Set 200 , at any time, can perform an intercom call to any other Telephone Set 200 . This is a strong advantage to prior art RF-based telephone system implementations, whereby the number of simultaneous intercom calls across the common communications channel in the overall telephone system was limited by the RF-channel capacity of the telephone system.
Telephone Set 200 Voice Messaging Capabilities
The Telephone Set 200 alone also has several inventive methods with respect to built-in advanced voice messaging capabilities.
The first inventive method regarding advanced voice messaging capabilities of the Telephone Set 200 is the ability to perform complete call recording capabilities when on an active call. The Telephone Set 200 can support two methods of call recording. One method is called “store-forward”, the second method is called “real-time” recording. The initiation of the call recording can be started by the user pressing a button on the Telephone Set device, or could be initiated by other system defined parameters, such as caller-id, time of day and user status. Also, the call recording can be started and stopped at any time during the conversation. In addition, the device could be setup such that all calls are recorded, without any user intervention. This can be done by an administrative setting in the Telephone Set, or the recording process can be controlled via appropriate SIP message requests received from the LAN Interface 15 .
An illustrative diagram of the inventive method is shown in FIG. 9 . This is one possible method, but one skilled in the art could devise of variations of the method. A call transmit and receive audio paths are compromised of audio streams, as is known in the art. These audio streams AUDIO_OUT 101 and AUDIO_IN 102 can be mixed, to create a summed audio output REC_OUT 103 . G 1 105 and G 2 106 represent gain control elements, such as variable gains and/or automatic gain controls that serve the purpose of equalizing the audio and receive transmit levels to produce a pleasing and useful summed audio output REC_OUT 103 . This audio output REC_OUT 103 represents the recorded audio conversation.
REC_OUT 103 can be directed to the local data store (via 105 ) on the Telephone Set 200 , and/or directed to the LAN Interface 15 (via 104 ). The former destination is used for “store-forward” method, and the latter destination is used for the “real-time” method, as explained in the next paragraph. The information would be sent on the LAN Interface 15 via one of several well known protocols (HTTP, SMTP, FTP, TFTP, SIP/RTP, and the like), or it could be done with a proprietary protocol. The destination for the recorded data would be any appropriate LAN device, on or off premises that would handle the recorded data in any way it deems appropriate.
For the “store-forward” method, the recorded call data is stored locally on the Telephone Set 200 . It could be stored in a volatile or non-volatile memory area. With this method after the call recording is complete, the user can manipulate the recording (playback, edit, and/or delete). Finally, the user would have the option of forwarding the recorded data out of the device via the LAN Interface. This can be done programmatically to control future calls, or automated, as well.
A drawback of the “store-forward” method is that the Telephone Set 200 may not have enough local data storage memory capacity for the recorded message. This is especially true if the call conversation is of a very long duration. Hence, the desire for the “real-time” method. In this method, the recorded data is immediately directed out of the device via the LAN Interface as soon as call recording is started. An appropriate amount of data buffering will generally be required to handle network latency issues.
An illustrative example of this method is when a user receives a call. The caller may want to leave a message for another person in the office. Instead of the user being bothered to find pen and paper, the user can press the appropriate keys on the Telephone Set 200 to initiate the call recording action, and select a named user using the Telephone Set 200 directory. (A directory is a common element in telephone sets). This named user would be the recipient for this recorded message. Stored in the Telephone Set— 200 data store is the named users e-mail address. Rather than a written note, the recipient in this example would receive the recorded call conversation as a voice file or audio capable file attachment to an e-mail. This e-mail message would be received in their e-mail client inbox. Alternatively, the message could be delivered to a voicemail system, and recipient could receive the message via normal voicemail mechanisms.
A related inventive method is that some protocols may have limits on the amount of data they can handle per session. This is a common limitation of e-mail for example, (SMTP) systems. The Telephone Set 200 can be configured such that it is aware of these limits, and without user intervention, it can close a session, and re-open another session. This can apply to both the “store-forward” and “real-time” methods. For example, if the Telephone Set 200 is using the SMTP protocol to send the recorded data as appropriate audio data file attachments, it may be aware that the e-mail system is limited to accepting only files less than one megabyte in size. At each one megabyte (or less) data boundary, the Telephone Set 200 would close the present SMTP session, and restart another one. This process would be repeated as long as call record data is still available. Sending the recorded audio in a series of related parts, each smaller than the relevant, expected or learned, data attachment size barrier. This makes the feature much more convenient and useful for the end user.
Another inventive method regarding advanced voice messaging capabilities of the Telephone Set 200 is call monitoring capabilities when on an active call. This inventive method is significant, because previous prior art either did not have this capability, or required the interaction of the telephone set with other system devices such as a central server or conferencing device. This provides significant economic and deployment advantages for those market segments that require this capability. (e.g. the call center industry). This example of a call monitoring method uses use the “real-time” method described above. FIG. 10 shows, in a similar fashion to call recording, how the call conversation data stream MON_OUT 110 is created and directed out the LAN Interface. It also shows how a remote call monitoring agent can not only listen to the active call, but optionally discretely inject their voice (from MON_IN 111 ) to the monitored Telephone Set 200 user (but not to the caller). Gain control elements 112 , 113 and 114 are used for the same purposes as recording. As is obvious, there are a number of permutations of interactions between groups of 3 or more connected persons on this system.
The following is one preferred method illustration of how a call monitoring agent would use this feature. A call monitoring agent who wants to monitor the call would activate this feature by initiating a SIP call (using SIP INVITE message) to the desired Telephone Set 200 . The SIP URI would indicate that this is a call monitor request. The Telephone Set 200 would not audibly alert the user, and may not give any visual feedback to the user. The software in the Telephone Set 200 silently accepts or rejects the INVITE, depending on administrative settings in the Telephone Set 200 . If accepted, a regular SIP/RTP session would be established, as is familiar to one skilled in the art. The monitoring agent would be listening to the call conversation of the Telephone Set 200 , and the monitoring agent can discretely make comments to the local user of the Telephone Set 200 . Other parties to the conversation would not hear comments by the call monitoring agent.
It is noted that call recording and call monitoring activities can be both active at the same time on the same Telephone Set device.
Another inventive method regarding advanced voice messaging capabilities of the Telephone Set 200 is voice recording capabilities when the device is not on an active call. This capability would allow the user to record a voice message into the device, and direct that message outwards via the LAN Interface 15 . This can be accomplished by the “store-forward” or “real-time” methods described above. FIG. 11 shows, in a similar fashion to call recording, how the recorded voice VOICE_OUT 121 is created and directed to the local data store (via 122 ), or directed out the LAN Interface 15 (via 123 ).
An illustrative example of this method is where a user wants to quickly deliver a message to other people. Instead of using a PC, and sending a regular e-mail, the user can record their voice message into the phone. Using the Telephone Set 200 directory, the user can select user(s) or groups to where this voice message would be externally delivered. By way of example, E-Mail (SMTP) would be a common delivery method. Recipients then could receive the message in their e-mail client inbox. Alternatively, the message could be delivered to a voicemail system, and recipients could receive the message via normal voicemail mechanisms.
Another inventive method regarding advanced voice messaging capabilities of the Telephone Set 200 is its optional ability to interface and manipulate directly with external LAN or WAN unified messaging storage services. Common to the art of unified messaging storage, an element of the art is a user having an option of handling their voicemail messages via their PC e-mail inbox, using the common POP3 or IMAP4 protocols. Conversely, the Telephone Set 200 could also handle the voicemail message. But with the prior art, the interaction with the POP3 or IMAP4 protocols are handled and coordinated by the central server. This inventive method refers to the Telephone Set 200 being able directly perform the POP3 or IMAP4 protocol interaction. The Telephone Set 200 would have appropriate protocol settings resident in the phone to become in some senses an e-mail client or a client of the unified message storage server (or both). These setting are entered by an appropriate administrative method.
An illustrative example of this method is where a user receives a voicemail message in their unified messaging storage server. They receive notification of this message in their e-mail inbox, or by their phone message-waiting lamp (or other methods such as stutter dial tone). If the user handles the message from the phone, the phone device will interact directly with the unified message storage server. If the user reviews the message, and deletes the message, the message will typically no longer appear in their e-mail inbox (assuming IMAP4 protocol is in use).
Telephone System 100 Voice Messaging Capabilities
Beyond the advanced messaging capabilities of the Telephone Set 200 , the Telephone System 100 also has an inventive method with respect to providing advanced system-wide voice messaging capabilities with a multitude of Telephone Set 200 devices. Due to the many deficiencies and limitations of the prior art, commercial voice-message implementations proved to be dismal in providing capable business-quality telephone system voice messaging services.
An inventive method described following provides common business-quality voice messaging services, with the “plug and play” spirit of the system in mind. These methods relate to common voicemail/auto-attendant related features. Specifically, these are audio greetings, and “dial-by-name” feature. These features are familiar to one skilled in the art. The inventive methods relate to how these features are coordinated and delivered amongst a multitude of Telephone Set 200 devices. This does not preclude the Telephone System 100 operating with a conventional centralized voicemail/auto-attendant device or service.
The inventive method regarding advanced voice messaging capabilities of the Telephone System 200 is the appropriate sharing of audio greeting and operational configuration files between Telephone Set 200 devices. At a minimum, a typical voicemail/auto-attendant function requires audio greeting files such as welcome greetings, common system messages and individual user greetings. Configuration files would include such common functional information as time/date operating modes, number of rings before answering calls, caller-id matching settings and the like, to permit this type of configuration information is familiar to one skilled in the art.
As previously described, each Telephone Set 200 knows details about other Telephone Set 200 devices in the network. Each stores the network addresses, names, associated user names, intercom numbers and various capabilities of the others. Using this information, each device can retrieve individual user greetings, and the associated user data, and store this data locally on each the Telephone Set 200 . By doing this, each Telephone Set 200 has the minimal capabilities to handle voicemail/auto-attendant capabilities servicing calls terminated on this device from the FXO port(s), or from the LAN/WAN network.
As an illustrative example, When each user sets up a Telephone Set 200 , the user will be prompted to record a user greeting and the user could also record the main system greeting. This user greeting would be stored locally on the Telephone Set 200 . In addition, the users are prompted to enter their full name (e.g. Bob Smith). Conversely, these greetings and information could be retrieved from a centralized configuration server.
Once a Telephone Set 200 is initialized, and in the Device Ready state (as described previously), then the Telephone Set 200 , can proceed to retrieve the user greetings and user information from the other Telephone Set 200 devices in the system. Various protocols of transferring this information across the LAN Interfaces 15 can be used, such as TFTP, FTP, HTTP, SIP/RTP and SCP. The welcome greeting would be administered specially so that it can negotiate which greeting to use amongst the system. Methods would include allowing only one welcome greeting to be recorded in the system, using only the welcome greeting with the latest recording date, or retrieving the welcome greeting from a centralized configuration server.
Once the Telephone Set 200 has collected all the necessary greetings and information, it is now trivial to allow the device to competently perform voicemail/auto-attendant functions familiar to one skilled in the art. The Telephone Set 200 can handle voicemail/auto-attendant functions for calls received on the attached FXO Circuit 10 , or via the LAN/WAN Network 6 . Having the information resident in each Telephone Set 200 allows the Telephone System 100 to independently handle voicemail/auto-attendant functions even if another user's Telephone Set 200 is then off-line for any reason. This provides robust and reliable (non-centralized) system operation.
The recorded voicemail message could be handled by any of Telephone Set— 200 devices in Telephone System 100 . Various methods of delivering the recorded voicemail message to the intended recipient(s) are possible. For illustrative purposes, the voicemail messages can be sent to the recipient via e-mail methods (e-mail method), where the recipient can receive the message in an assigned e-mail inbox. Alternatively (or in addition), the voice mail message can be transferred directly (transfer method) to the intended recipient's actual Telephone Set 200 . This transfer could use various LAN protocols such as TFTP, FTP, HTTP, SIP/RTP and SCP. The recipient could listen to the voicemail message on the recipient's Telephone Set 200 in the usual manner. The e-mail method is attractive, especially if the Telephone Set 200 has limited amounts of memory storage.
A combination of the e-mail and transfer methods is attractive. The following is an illustrative example. If the transfer method is used, the user can manipulate the voicemail on the Telephone Set 200 in the usual manner, such as navigating through key and LCD display prompts and listen using the Telephone Set 200 handset or speaker. At this time the user can listen to the message, delete it, or have the option of forwarding the message to the user's (or other) e-mail addresses. An administrative setting in the Telephone Set 200 could also automatically e-mail the message to pre-determined addresses under various scenarios. These could include scenarios such as if the local storage is full, or based upon time/date/holiday and caller identification settings and some simple (or complex) rules.
The e-mail addresses of possible recipients can be known by various methods. One method is when a user can enter in a Telephone Set 200 by administrative methods that use actual name and user e-mail address. This information is then shared with other Telephone Set 200 devices in the Telephone System 100 . Alternatively, the Telephone Set 200 can interact with a central user information server, such as a LDAP server. For example, for one skilled in Lightweight Directory Access Protocol (LDAP) servers, one can retrieve information such as e-mail address associated with a user.
The voice messaging capabilities of Telephone System 100 are significant, for they can deliver advanced capabilities using only one or more Telephone Set 200 devices. This provides significant cost and complexity advantages for the end customers who want advanced voice messaging capabilities.
ADDITIONAL EMBODIMENTS
An additional embodiment of Telephone System 100 as represented in FIG. 1 , is that each Telephone Set 200 does not necessarily need to have a telephone line connected to its FXO Circuit 10 . The Telephone System 100 still works normally. When the specific Telephone Set 200 is queried by a SIP OPTIONS method, it can simple indicate that there is no FXO port resource available.
This notion leads to additional embodiments of Telephone Set 200 . Additional embodiments of Telephone Set 200 could have no FXO circuit, but it could also have multiple FXO circuits. Again, the SIP OPTIONS query would make this resource information known to the Telephone System 100 .
An additional embodiment of Telephone Set 200 is one that uses different physical LAN interfaces such as wireless interfaces (802.11) or different wired interfaces such as emerging higher speed LAN interfaces or optical LAN interfaces.
An additional embodiment of Telephone Set 200 is one that is created solely as a softphone, running on a PC or a handheld device.
But in the spirit of the invention, these additional embodiments of Telephone Set 200 would have appropriate software to participate in the inventive Telephone System— 100 .
An additional embodiment of Telephone System 100 is one that uses alternative LAN protocols. To one skilled in the art, many imaginative alternative or new LAN protocols could be used to implement the inventive spirit of Telephone System 100 .
ALTERNATIVE EMBODIMENTS
In the server-less and “plug and play” spirit of the Telephone System 100 there are many imaginative alternative embodiments of this invention. FIG. 3 shows an example of an alternative embodiment. In this Telephone System 700 , any combination of Feature Device or Service 5 - 1 through to 5 -N would be part of the telephone system. Telephone Set 2 - 1 through 2 -N are shown without analog telephone lines connected, but this does not need to be the case. Telephone Set 2 - 1 through 2 -N are optional in Telephone System 700 , for call devices could be provided from other means such as PCs, cordless or wireless handset devices.
An illustrative functional block diagram of an optional feature device is a Voice Messaging 200 device, as shown in FIG. 4 . It is a device that could provide centralized voicemail, autoattendant, IMAP4 unified voice mail server, music-on-hold (MOH), overhead paging, door opener and door phone functionality familiar to one skilled in the art. In addition to previously described components, it comprises of the following: a non-volatile data storage area 54 (for storage of configuration information, and voicemail and greeting messages); the MOH Interface(s) 50 , Doorphone/Opener Interface(s) 51 and Overhead Paging Interface(s)— 52 are familiar to one skilled in the art. Other than the inventive Telephone System concepts of the invention, the elements are well-known to one skilled in the art and will not be described in detail.
This alternative embodiment opens the concept that some of the advanced voice messaging capabilities resident in the Telephone Set 200 or Telephone System 100 can be partially or completely provided by the Voice Messaging 200 device. For example, having voicemail in a separate device can provide more cost effective mass storage of messages. In addition, this is a convenient device to provide the MOH, overhead paging and door opener/phone functionality. Voice messaging storage and access could also be provided as a third-party service available over the Internet.
Another illustrative functional block diagrams of other optional feature devices are a Multi-Port FXO 800 device and a T1/E1 Access 400 device, as shown in FIG. 5 and 6 respectively. These feature devices would provide additional PSTN access methods for the inventive telephone system. The Multi-Port FXO 800 device can alleviate the need to route an analog telephone line to a Telephone Set 200 . This simplifies wiring in the office. The T1/E1 Access 400 device would allow the Telephone System 700 to expand greatly the PSTN access capabilities of the system. This is in contrast to prior art for a telephone system without central control, which was limited to accessing only FXO ports. As previously described for Telephone Set 200 , whereby it performs forking upon reception of a incoming FXO call, these devices would perform the forking of incoming PSTN calls as is appropriate for the telephone system. The use of these devices may also be characterized as delivery of additional voice processing services over the system.
An illustrative functional block diagram of another feature device is a Multi-Handset Cordless Base Station device 600 , as shown in FIG. 7 . The Multi-Handset Cordless Base Station Radio 80 handles the Cordless Handsets 82 , as is known in the art. A multitude of Multi-Handset Cordless Base Station devices 600 could be present in the system, and coordinate handset roaming/handoff activities between each other by signaling appropriately over the LAN/WAN Network 6 . The advantage of a device like this is to add cordless phone capabilities to the Telephone System 700 . This can also be accomplished by having handset devices that operate directly on well-known 802.11 or Wi-Fi wireless technologies.
An illustrative example of another feature device would be a common office router that is enhanced with SIP proxy and registrar services. This could handle more gracefully the handling of incoming SIP calls originating from the WAN, without resorting to port forwarding. Devices in Telephone System 700 can register with this device, as usual, and then this device can handle the appropriate forking of incoming WAN SIP calls.
It is not out of the question for one to create a complex feature device that combines multiple features such as voice mail, autoattendant and PSTN access, or other functions. But within the spirit of the inventive telephone system, it would be an optional device, and the operation of the Telephone System 700 would not be wholly dependent on its presence. Some telephone system features may be missing of course, but basic functionality of telephone sets would be required.
There is also the concept of a Feature Service, such is commonly found out in the WAN environment (i.e. Internet). These services may not be able to be discovered automatically, but their location would be entered into any appropriate device by administrative methods known in the art. Examples of such feature services could include WAN PSTN calling services (DeltaThree, Net2Phone, . . . ), voice recognition services, centralized voice mail storage and retrieval services, and call conference services.
Again, the spirit of the invention of this telephone system, is that a Feature Device or Service 5 - 1 through to 5 -N, such as the illustrative examples above, can go through similar system discovery methods described previously, and are not controlled by a central server, but are provided using the systems and methods of this invention.
Conclusion, Ramifications and Scope
In the basic embodiment of the inventive Telephone System 100 , a full-featured phone system is created using solely one or more inventive Telephone Set 200 —devices. In the basic Telephone System 100 , multi-line PSTN and VoIP calls can be handled, and advanced voice messaging capabilities can be provided. There is no central control point in the inventive Telephone System 100 . This system concept provides advantages to end users in being able to affordably scale down to offices as small as one user, and improves system reliability because there is no central point of failure.
To those skilled in the art to whom this description is addressed, it will be apparent that the embodiments previously described may be varied to meet particular specialized requirements without departing from the true spirit and scope of the invention disclosed. The previously described embodiments are thus not to be taken as indicative of the limits of the invention, but rather as exemplary structures thereof. Thus the scope of the invention should be determined by the filed claims and their legal equivalents, rather than by the examples given. | An apparatus and method for effecting sophisticated telephony services using hybrid POTS and VoIP transport without resorting to central servers or PBXs is provided. Key to the system is the use of on-phone processing capabilities comprising several A-D/D-A, memory and addressing, audio-mixing, program memory and programmable computing circuits or components. The system performs required IP and VoIP protocol stacks (UDP, RTP, and SIP for example) and POTS functionality. Optionally, fail-over from set-power may be provided using POTS line voltages.
The phones of this invention self-configure dependent upon the network environment to which they are attached, and direct call and other functionality digitally under programmed computing control, thus being highly configurable; redundancy between networked phone devices adds robustness.
The telephone system is comprised of independent telephony devices operating on a LAN and/or WAN TCP/IP-based connection The inventive concept allows for greater system scalability with lower cost, reliability and flexibility. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 60/257,081, filed Dec. 20, 2000, which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
The present invention relates to an electronic sensor system for monitoring a window, door or other opening associated with a vehicle or vehicle interior, and in particular a system for mounting, aiming, and/or packaging such a sensor system.
In recent years, electronic sensors have not been utilized for obstacle or intrusion detection in vehicle window systems because of complexity and mounting limitations. Typically, obstacle detection has been based on limit switches, window motor characteristics, or ultrasonic monitoring signals that do not have precise mounting or alignment requirements. Small variations in detection system mounting do not significantly effect the performance of these sensor systems. The variations in trim components and installer techniques obviates the use of potentially more sensitive and thus accurate monitoring systems which are subject to performance degradation as a result of misalignment with respect to an ideal mounting configuration.
So-called tolerance stack-up results due to the variability in the physical relationship between a lens to emitters or detectors of an obstacle detection system, emitters or detectors to a circuit board on which they are mounted, the circuit board to the respective housing, the housing to vehicle trim and/or the respective door panel, and vehicle trim and/or the door panel to the door sheet metal. Variations from vehicle to vehicle, door to door, in system installation techniques within the vehicle factory, and in system installation techniques by after-market installers can all add to the tolerance stack-up problem.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an obstacle detection system which includes a monitoring sensor system and a mounting system. In a first embodiment, the obstacle detection system is adapted for use in a vehicular setting. The mounting system presently disclosed allows an installer to make aiming adjustments, in the factory or field, to account for the tolerance stack-up problems described above. The system includes a housing for mounting the monitoring sensor system to minimize cross-talk and interference between the transmitter and receiver sections, to limit sensor system movement based on vehicle component and factory installation variations, and to enable gross and fine aiming to accommodate field programmability.
In a preferred embodiment of the invention, a circuit board is disposed within a cradle assembly which, in turn, is mounted in or integral to the housing to position the obstacle detection sensor in proximity with the target structure or region of the vehicle. The cradle in one embodiment is an enclosure for the circuit board, fabricated from a resilient material such as plastic. Importantly, the cradle does not obstruct or interfere with the operation of the transmitter or receiver associated with the sensor disposed on the circuit board. The cradle may facilitate sensor removal and replacement without requiring the removal of the housing. Thus, once the housing is properly aligned relative to the vehicle trim, maintenance can be performed on the sensor without effecting such alignment. The sensor housing is mounted to the interior vehicle trim, door panel, and/or door sheet metal and ensures consistent mounting regardless of interior trim or factory installation variations. In addition, integral adjustment mechanisms are incorporated in further embodiments to provide the ability to make adjustments in either an initial installation environment or after the vehicle is fielded. In yet another embodiment, the circuit board is comprised of plural subsections interconnected by flexible circuit board, enabling accurate alignment of each subsection with respect to the environment to be monitored. Thus, accurate installation is realized through features which locate the housing relative to the vehicle sheet metal or some other consistent reference surface, through adjustment tools associated with the housing which it is installed, or both.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
These and other objects of the presently disclosed invention will be more fully understood by reference to the following drawings, of which:
FIG. 1 is a diagrammatic view of components of an obstacle detection system according to the presently disclosed invention;
FIG. 2 is a perspective exterior view of a first embodiment of an obstacle detection system housing according to the presently disclosed invention;
FIG. 3 is a perspective interior view of the housing of FIG. 2; and
FIG. 4 illustrates the placement of the obstacle detection system of the presently disclosed invention in association with the sheet metal of a vehicle door;
FIG. 5 is a diagrammatic view of components of a further embodiment of the obstacle detection system of FIG. 1;
FIG. 6 is a plan view of a circuit board for use in the obstacle detection system embodiment of FIG. 5;
FIG. 7 is a perspective view of a lens module for use in the obstacle detection system embodiment of FIG. 5;
FIG. 8 is a cross-sectional view of a fastener for the presently disclosed obstacle detection system;
FIG. 9 is a plan view of an aperture for receiving the fastener of FIG. 8;
FIG. 10 is an elevation view of a first alignment mechanism for use with the presently disclosed obstacle detection system; and
FIG. 11 is an elevation view of a second alignment mechanism for use with the presently disclosed obstacle detection system.
DETAILED DESCRIPTION OF THE INVENTION
The presently disclosed invention enables the accurate installation of an obstacle detection system, such as for use in conjunction with a vehicle window, as well as the alignment of components of the system for optimal performance. An obstacle detection system according to the presently disclosed invention is comprised of the active circuitry responsible for detecting an obstacle and a mounting subsystem which enables accurate alignment of portions of the active circuitry.
FIG. 1 provides a schematic illustration of a circuit board employed as part of the active circuitry. The individual active components and their function may be as described in U.S. Pat. No. 5,955,854, owned by the same assignee as the present application and incorporated herein by reference. With reference to FIG. 1, an energy field may be generated proximate a window opening, in which a power window operates, through the use of infrared (IR) light emitting diodes (LEDs) 12 . Energy reflected off one or more objects or surfaces in the path of the emitted energy is detected by co-located IR detectors 14 . A processor 16 , such as a specially-programmed microprocessor with associated memory, is used to control the operation of the emitters 12 and to analyze the output of the detectors 14 . However, it should be understood that other components may be substituted to the extent that such components work in concert with the inventive concepts disclosed and claimed herein.
One or more circuit boards 20 are employed for mounting the circuitry. Because the window opening to be monitored is typically non-planar, and as a result of the varying active fields of the emitters 12 and detectors 14 , it is often necessary to dispose the active fields of the emitters 12 and detectors 14 in different planes. In the embodiment illustrated in FIG. 1, a circuit board 20 used to mount the active detector system components is comprised of two rigid circuit board portions 22 , 24 interconnected by a flexible circuit board portion 26 . Signal pathways 30 between the processor 16 and the emitters 12 and detectors 14 are shown schematically. Depending upon the particular physical environment to be monitored, two or more circuit board portions may be interconnected at a variety of locations by flexible portions. The embodiment of FIG. 1 is merely one example.
The portion of the presently disclosed obstacle detection system used to mount the system in association with the vehicle typically includes a housing 40 , such as in the exemplary embodiment of FIG. 2 . Preferably, such a housing 40 is fabricated of a material which is complimentary to that of the vehicle trim. Considerations including environment temperature fluctuation, ultraviolet exposure, and physical jarring must be borne in mind in selecting appropriate materials for the housing 40 .
Disposed on a surface of the housing are one or more lenses 42 . These lenses may be transparent to the active wavelengths employed by the emitters 12 and detectors 14 , or may be selected from materials or may be provided with a physical configuration which imparts a desired beam shaping or focusing effect on the transmitted and reflected energies. The illustrated housing embodiment of FIG. 2 is particularly adapted for installation in a lower front corner of a vehicle window, as illustrated in FIG. 4 . Such a housing may be used to accommodate other circuitry in addition to that of an obstacle detection system.
FIG. 3 provides a perspective illustration of the reverse side of the housing 40 shown in FIG. 2 . In this embodiment, two discrete circuit boards 44 , 46 are employed rather than the single, multi-segmented circuit board 20 of FIG. 1 . Optical isolation between transmit and receiver elements is provided by an opaque or non-transmissive barrier integral to the housing. The placement of the housing 40 in relation to a vehicle door assembly is shown in FIG. 4 .
FIG. 5, similar to FIG. 3, illustrates the reverse side of a housing 60 for use in mounting obstacle detection circuitry proximate an aperture to be monitored. In this case, however, the circuit boards 44 , 46 have been replaced with a circuit board receptacle 62 or “cradle.” The cradle 62 , which in a preferred embodiment is formed of extruded plastic, is adapted for receiving a specifically configured circuit board or circuit boards and for enabling the accurate placement of the circuit board(s) in relation to the housing 60 . One or more stanchions 64 are provided in the illustrated embodiment in order to accurately locate one or more circuit boards within the cradle 62 . The cradle 62 may also be provided with one or more mounting flanges 58 for securing the cradle 62 to the housing 60 . Threaded fasteners, heat tacking, gluing, or other fastening techniques may be employed to attach the cradle 62 to the housing 60 . An energy barrier 68 , such as a rectangular plane integral with the cradle 62 , is also preferably provided in order to minimize light leakage between an emitter element and a receiver element, as described in further detail below. A protective cover (not shown) may also be provided once a circuit board and associated elements have been installed in the cradle 62 .
One form of circuit board particularly suited for installation in the cradle 62 of FIG. 5 is illustrated in FIG. 6 . This circuit board 66 is provided with two openings 70 located for installation about the stanchions 64 of the cradle 62 . Fasteners such as screws may also be employed to locate the circuit board 66 on the stanchions 64 . The circuit board 66 of FIG. 6 is also provided with a slot 72 to enable the board 66 to be installed about the energy barrier 68 of the cradle 62 . Receptacles 74 for electrically interfacing with emitter and detector elements are also provided in conjunction with the circuit board 66 . Active circuit elements may be disposed on the circuit board as necessary in a fashion known to those skilled in the art.
While the embodiments of FIGS. 1 and 3 are suitable for many applications, in others, the provision of the emitter elements 12 and detector elements 14 remote from the respective lens 42 leads to tolerance stack-up. In other words, any misalignment of an emitter LED 12 , for example, may be exacerbated by the respective lens 42 . Similarly, if a receiver element 14 is not accurately aligned with a respective lens 42 , an obstacle may not be detected or a false alarm may be triggered.
To address the effect of tolerance stack-up due to misalignment between a lens and an emitter or detector, also referred to as boresight error, it is preferable to minimize the distance between the lens and the respective emitter or detector elements and to eliminate independent movement therebetween. One aspect of the presently disclosed invention addresses this issue by providing an integrated lens module 80 , as depicted in FIG. 7 . One or more emitter or detector elements are accurately positioned within a mold for a lens, and the lens material is injected about the emitter or detector, thus forming an integrated module. Assuming the lens has been formed with the respective emitter or detector accurately positioned, such an integrated module eliminates any contribution to tolerance stack-up resulting from lens misalignment. As known to those skilled in the art, the lens module 80 forward surface may be molded to impart any necessary beam shaping, and is formed from a material chosen to have the desired impact (if any) on the energy transmitted therethrough. The active elements may also be associated with the lens after the lens has been fabricated. For instance, a bore may be formed in a pre-molded lens and the active element inserted then secured to the lens.
Electrical leads 82 in communication with the respective emitter or detector extend from a rear surface of the lens module 80 for connection to the remaining active circuitry of the obstacle detection system. For instance, lens modules 80 may be disposed in communication with receptacles 74 on the circuit board 66 of FIG. 6 and on either side of the energy barrier 68 integral with the cradle 62 of FIG. 5 . Physical features such as tabs 84 may be provided in conjunction with the cradle 62 for interference with a corresponding groove or keyway 86 disposed on a surface of the lens module 80 . Accurate alignment of the lens module 80 is thus provided. One tab 84 per lens module 80 is illustrated though more are provided in alternative embodiments.
Despite the reduction in tolerance stack-up afforded by the lens module 80 , it is mandatory that the housing 40 be accurately positioned with respect to the environment in which the detection system operates. While various positioning and fastening arrangements are available, one particularly useful system includes the use of a variant of the so-called “christmas tree” fastener for mounting the detection system to the door sheet metal. A christmas tree fastener is typically provided as a cylindrical post having plural conical projections disposed along the length of the post. As the post is forced through an aperture of diameter slightly greater than that of the post, the conical projections deform then return to shape, thereby applying back-pressure and resisting extraction from the aperture. The presently disclosed variant on conventional fasteners enables the accurate mounting of an obstacle detection system at a point which is common from vehicle to vehicle, regardless of overlying trim and customization.
Due to the round cross-section of the conventional christmas tree post, such fasteners are prone to rotation or other movement after being installed. To address this deficiency, the presently disclosed system, in one embodiment, employs at least one and preferably several modified christmas trees 90 to fasten the housing 40 , 60 to the vehicle trim. As shown in FIG. 8, the modification entails the formation of two parallel grooves 92 on opposite sides of the post 94 . Both grooves are substantially orthogonal to the length of the post 94 and parallel to the conical projections 96 .
While the prior art has employed a circular aperture for receiving conventional christmas tree fasteners, the presently disclosed system includes the use of a key-hole shaped aperture 100 , such as illustrated in FIG. 9, formed in the vehicle trim 108 or other mounting surface. The modified christmas tree 90 is inserted into a substantially circular opening 102 until the conical projections 96 have passed through the circular opening 102 . The grooves 92 are then aligned with a slot 104 extending in the vehicle trim 108 from the circular opening 102 . Preferably, the conical projection 96 most proximate the grooves 92 is in physical contact with the vehicle trim 108 adjacent the key-hole aperture 100 when the grooves 92 are aligned with the slot 104 to minimize relative movement of the fastener 90 .
In one embodiment, the slot 104 of the key-hole aperture 100 includes one or more locking tabs 106 which will either physically interfere with the post 94 , thus holding the post in place, or will allow the post to pass therebetween and will then act to resist movement of the post towards the circular opening 102 . In the former case, receptacles (not shown) may be provided within the grooves to receive the tabs 106 .
While one such modified christmas tree fastener 90 and key-hole shaped aperture 100 may suffice, it is believed preferable to provide plural fasteners 90 and apertures 100 to ensure proper gross alignment for the housing 40 , 60 of the presently disclosed obstacle detection system.
Another form of gross alignment mechanism for the detection system is illustrated in FIG. 10 . The cradle 62 of FIG. 5 is shown schematically in elevation with respect to the housing 60 . A multi-position bracket 110 enables one end of the cradle to be positioned at one of various positions relative to the housing 60 inner surface. A resilient member 112 such as a leaf spring is preferably provided in conjunction with each position in the bracket to resist movement of the member installed therein. Physical features such as tabs or keys matable with sockets or grooves may also be provided to positively engage the member installed in the bracket 110 . The field of view of the active elements located at the opposite end of a circuit board 66 installed in the cradle 62 is thus adjusted as the cradle 62 is relocated from one bracket 110 position to another. In this case, the stanchions 64 projecting from the housing 60 into the bottom of the cradle 62 are intended primarily to resist lateral motion of the cradle 62 , parallel to the major surface of the housing 60 .
In an alternative embodiment, the circuit board 66 is engaged on a variant of the cradle 62 , the cradle itself supporting a multi-position bracket 110 such as that shown in FIG. 10 . Further still, in the absence of a cradle 62 , a circuit board 20 such as shown in FIG. 1 may be disposed within one of the positions in such a bracket 110 mounted in the housing 40 . Such a bracket 110 may be employed in a further embodiment in conjunction with one or more subsections of a multi-sectioned circuit board 20 as shown in FIG. 1 . Moreover, the bracket 110 , while illustrated as a discrete unit, may be provided as a plurality of mutually-parallel ribs on the surface of the vehicle trim.
Despite the flexibility afforded by the multi-position bracket 110 of FIG. 10 and its ability to be adapted for use with a cradle 62 , a circuit board 66 to be installed in such a cradle 62 , or independent circuit boards 44 , 46 , a circuit board assembly 20 such as that shown in FIG. 1, it is often necessary to enable further refinement of the field of view of the obstacle detection system's active elements. To this end, one embodiment of the presently disclosed invention, illustrated in FIG. 11, provides the ability to finely adjust a circuit board 120 orientation in three dimensions relative to a housing.
The circuit board 120 of FIG. 11 may represent the segmented circuit board 20 of FIG. 1, either of the unitary circuit boards 44 , 46 of FIG. 3, or the cradle-mounted circuit board 66 of FIG. 6 . In addition, the cradle 62 of FIG. 5 may be mounted to the housing 60 in the same manner. In any case, the circuit board 120 is in contact with a projection 124 extending from a mounting surface 122 . The mounting surface 122 may be represented by the housing 40 (FIG. 3 ), the housing 60 (FIG. 5 ), or the cradle 62 (FIG. 5 ). As shown, the projection 124 is frusto-spherical, though any shape affording a pivot point in contact with the circuit board 120 or other surface to be aimed may be substituted. Additionally, while the projection 124 is preferably disposed on the mounting surface 122 , it may also be formed on the circuit board 120 itself and extend into contact with the mounting surface 122 .
The circuit board 120 is mechanically joined to the underlying mounting surface 122 through the use of at least three height-adjustable fasteners 126 such as screws. Resilient elements 128 such as springs are preferably provided intermediate the circuit board 120 and the mounting surface 122 , about the fasteners 126 , in order to maintain the circuit board 120 in a desired position relative to the mounting surface 122 . By adjusting the height of one or more fasteners 126 , the angle of inclination of the circuit board 120 is manipulated. Depending upon the pitch of the fastener 126 threads, very fine adjustment of the circuit board orientation relative to the housing may be achieved.
These and other examples of the invention illustrated and described above are intended by way of example and the actual scope of the invention is to be limited solely by the scope and spirit of the following claims. | An obstacle detection system for vehicular environments including a monitoring sensor system and a mounting system is disclosed. An installer can make aiming adjustments, in the factory or field, to account for tolerance stack-up. The system includes a housing for mounting the monitoring sensor system to minimize cross-talk and interference between transmitter and receiver sections, to limit sensor system movement, and to enable gross and fine aiming adjustments. In one embodiment, a circuit board is disposed within a cradle assembly which, in turn, is mounted in or integral to the housing to position the obstacle detection sensor as necessary. The cradle in one embodiment is an enclosure for the circuit board. The sensor housing is mounted to the interior vehicle trim, door panel, and/or door sheet metal and ensures consistent mounting regardless of interior trim or factory installation variations. Integral adjustment mechanisms are incorporated for adjusting the orientation of the sensor system. The circuit board may be comprised of plural subsections interconnected by flexible circuit board, enabling accurate alignment of each subsection with respect to the environment to be monitored. | 6 |
REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of U.S. patent application Ser. No. 09/498,523 of Michael A. Kamara filed Feb. 4, 2000 now abandoned and entitled “Jewelry With Battery-Illuminated Medallion”.
BACKGROUND
1. Field of the Invention
The present invention relates to jewelry. More particularly, this invention pertains to a necklace or bracelet that includes an illuminated medallion.
2. Description of the Prior Art
There exists a substantial market for jewelry of a whimsical nature. Unfortunately, the design of jewelry that can be sold at mass market prices while offering an eye catching effect, such as artificial luminance, is complex and difficult. To achieve such an effect, the jewelry must include a power source, preferably compact. In addition, inexpensive prior art jewelry incorporating a battery-powered device has generally been of limited useful life since inexpensive designs fail to permit battery replacement.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing and other shortcomings of the prior art by providing an article of jewelry. Such article includes an elongated flexible conductor having an exterior coating of non-conductive composition. The conductor comprises a loop having first and second internal discontinuities. A clasp is located within the first discontinuity and a medallion is located within the second discontinuity. The clasp includes a battery in electrical communication with the conductor and the medallion includes an electro-luminous device in electrical communication with the conductor.
The preceding and other features and advantages of the present invention shall become further apparent from the detailed description that follows. Such description is accompanied by a set of drawing figures in which numerals, corresponding to those of the written description, are associated with the features of the invention. Like numerals refer to like features throughout both the written description and the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a necklace incorporating the invention superimposed upon a wearer shown in shadow outline;
FIG. 2 is a cross-sectional view of the coated conductor of the invention;
FIG. 3 is an exploded side elevation view of the clasp of an article of jewelry in accordance with the invention;
FIG. 4 is an side elevation view in cross-section of an assembled clasp in accordance with the invention; and
FIG. 5 is a cross-sectional view of the luminous medallion of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the drawings, FIG. 1 is a perspective view of a necklace 10 incorporating the invention superimposed upon a wearer shown in shadow outline. The necklace 10 generally comprises a coated conductor 12 comprising, as shown in the cross-sectional view of FIG. 2, an internal conductor or wire 14 having a coating 16 of appropriate non-conductive material. An example of a suitable coated conductor is NYLON-coated wire. Such a conductor has the advantageous quality of avoiding “kinking” when bent.
Returning to FIG. 1, the coated conductor 12 is formed into a loop for hanging about a wearer's neck (in the case of the necklace) or wrist (in the case of a bracelet) with discontinuities provided for incorporation of an illuminated medallion 18 and a clasp 20 housing a battery structure. As will be seen, an electrical circuit is formed that includes the battery housed within the clasp 20 , a battery-powered light emitting device of the medallion 18 and the conductor 14 . Such electrical circuit actuates the medallion to emit illumination when energized by the closing of the clasp 20 . Thus the clasp 20 serves both to secure the necklace 10 and to house a replaceable battery. By allowing battery replaceability, the useful life of the necklace 10 is not limited by that of the battery, permitting the fabrication of higher quality jewelry as opposed to the lower quality “throw away” items of the prior art.
FIG. 3 is an exploded side elevation view of the clasp 20 of the invention and FIG. 4 is a side elevation view in cross-section of the clasp 20 when the assembly is closed. The clasp 20 has been carefully designed to facilitate the ready removal and replacement of a battery 22 that provides the power for illuminating the medallion 18 . The battery 22 is preferably of the nickel cadmium type characterized by an anode surface 24 of lesser diameter than the cathode surface 26 .
The clasp 20 includes coating upper and lower caps 28 and 30 , respectively. The caps are preferably made of molded plastic or other resilient material. The caps 28 and 30 of the clasp 20 are particularly designed to facilitate easy access to the interior of the chamber formed therebetween for removal and/or replacement of battery 22 . Each cap 28 and 30 includes a rim 32 and 34 , respectively, that protrudes outside the outer diameter of an associated sidewall. In the case of the upper cap 28 , the rim 32 protrudes outside the outer diameter of an annular sidewall 36 , while in the case of the lower cap 30 , the rim 34 protrudes outside the outer diameter of a sidewall 38 .
The rims 32 and 34 greatly facilitate the ability of one to grasp the caps 28 and 30 independently. In addition, as can best be seen in FIG. 4, the clasp 20 has been carefully dimensioned so that, when closed, the sidewall 38 of the lower cap 30 is forced outwardly by the maximum outer diameter of the enclosed battery 22 so that a press-fit is obtained with the interior of the sidewall 35 of the upper cap 28 . Such interaction is obtained by careful dimensioning of the inner diameter of the sidewall 38 with the dimensions of the battery 22 and the outer diameter of the sidewall 38 with the inner diameter of the sidewall 36 .
In addition to the locking arrangement illustrated in FIG. 4, a tight pressure fit exists between the battery 22 and the interior of the rim 34 of the lower cap 30 that retains the battery 22 within the clasp 20 , even when the two caps 28 and 30 are disengaged from one another. This permits one to use and wear the device as an ordinary piece of jewelry, unlocking the clasp 20 to remove the necklace, for example, from one's neck without concern that the battery 22 will be lost.
When appropriate (i.e. when battery replacement is required) this is easily accomplished by pushing a thin rod-like element upward through an aperture (not shown) that is provided extending through a bottom surface of the lower cap within the thickened central area of the rim 34 circumscribed by the inner circumference of the sidewall 38 .
Electrodes 42 , 44 are received within central recesses 46 , 48 at the thickened inner surfaces of the rims 32 and 34 respectively. Each of the rims 32 and 34 includes a tunnel 50 , 52 for receiving an end of the coated conductor 12 adjacent a loop discontinuity. Referring to FIG. 4 in particular, it can be seen that the portions of the ends of the coated conductor 12 interior to the rims 32 and 34 are stripped to expose the conductor wire 14 . The wire 14 is, in each case, joined to an electrode 42 or 44 , after being threaded through one of the tunnels 50 , 52 by crimping with a metal crimp bead to form a flat, square contact that cannot traverse backward through the tunnel 50 or 52 as each bead assembly is much larger than the tunnel through which it was originally received. As a result, no adhesives (for securing either electrodes or wires) are required within the interior of the clasp 20 .
FIG. 5 is a cross-sectional view of the medallion 18 of the necklace 10 . The medallion 18 comprises a spherical bead 54 , smooth or faceted, of transparent or translucent, clear or tinted, material that receives ends of the coated conductor 12 in the region of a second loop discontinuity. The ends of the coated conductor 12 , stripped to expose the interior conductor wire 14 , electrically contact positive and negative terminal receptors 56 and 58 of a light emitting diode (LED) 60 . The LED 60 is of the surface mounted type, permitting the arrangement of shown in FIG. 5 and may comprise, for example, a device commercially available under Part No. KPT 2021HD from Kingbright Corporation of City of Industry, California. Such a LED is available in red, blue, green, amber and white. The invention is, however, not limited to such device.
The bead 54 of the medallion 18 includes a diametrical hole 62 forming a channel therethrough. To assemble, the LED 60 is inserted into the channel after insertion of the surface mounted LED 60 therein with positive and negative terminal receptors 56 and 58 facing opposed channel entrances. The exposed conductor 14 at the ends of the stripped coated conductor 12 are separately inserted into the ends of the channel to contact the LED 60 . Once contact is made with one of the opposed terminals, an appropriate non-conductive adhesive, such as silicone glue, is injected into the channel and allowed to harden to maintain contact between that terminal and the conductor or wire 14 . This process is repeated to obtain secure contact between the wire 14 and each of the terminal receptors 56 and 58 , resulting in a simple, yet rugged configuration. The use of silicone glue assures that the channel will remain clear and in no way affect the appearance of the bead 54 when illuminated.
Employing a surface mounted LED 60 enables the use of a small bead-like medallion 18 that is illuminated from within. This is to be contrasted with illuminated medallion-type ornamentation that employs bullet mounted LEDs such at that taught in U.S. Pat. No. 6,122,933 issued to Stephen K. Ohlund on Sep. 26, 2000 for “Jewelry Piece”. Such LEDs operate at a higher voltage (requiring the use of multiple batteries and thereby necessitating a bulkier clasp) and, as in the above patent, requiring an arrangement other than the simple and durable arrangement of the invention in which wires enter into the interior of a bead to contact opposite sides of a LED. This is due to the fact that bullet-mounted LEDs are bulkier (approximately 0.75 mm vs. 3 mm in cross section) than surface mounted LEDs and the output pins of such LEDs are parallel to one another, exiting the LED from the same side. Such terminal configuration prevents the mounting of such a source wholly within a small bead as in the invention. The mounting of the light source wholly within a relatively small bead 54 generates a more brilliant and dramatic effect than possible in devices limited to indirect illumination as a consequence of the use of bullet type LED sources such as that of U.S. Pat. No. 6,122,933.
When assembled, the necklace 10 (alternatively, a bracelet may by formed with a shortened coated conductor 12 ) is then operable as a piece of luminous jewelry with illumination emanating through the bead 54 of the medallion 18 since the LED 60 is in electrical contact with the battery 22 power supply through the conductor 14 when the clasp 20 is closed and secured as shown in FIG. 4 .
While this invention has been described with reference to its presently-preferred embodiment, it is not limited thereto. Rather, the invention is limited only insofar as it is defined by the following set of patent claims and includes within its scope all equivalents thereof. | A necklace or bracelet includes a luminous medallion. A conductor having a coating of non-conductive material is formed into a loop having two discontinuities. A clasp that houses a removable battery is fixed within the first discontinuity and a bead having an internally embedded LED is located within the second discontinuity. Electrical connections are made to electrodes located within the clasp by interior electrical conductors exposed at the stripped ends of the coated conductors that define one discontinuity. The conductors are fixed in electrical contact with the LED at the other discontinuity at the stripped ends of the coated conductor in the region of the second discontinuity. | 0 |
BACKGROUND
1. Field of the Disclosure
The disclosure generally relates to cross-device communications, and more specifically to techniques to reduce redundant copies of data across user and kernel space boundaries in a virtual memory address space.
2. Related Art
Central processing units (CPUs) in computing systems may manage graphics processing units (GPUs), network processors, security co-processors, and other data heavy devices as buffered peripherals using device drivers. Unfortunately, as a result of large and latency-sensitive data transfers required between CPUs and these external devices, and memory partitioned into kernel-access and user-access spaces, these schemes to manage peripherals may introduce latency and memory use inefficiencies.
For example, an exemplary computing system may include a CPU and GPU sharing a common memory address space, with each of the CPU and GPU having a page-locked buffer in kernel-access memory address space. Direct memory access (DMA) controllers may transfer data between the CPU buffer in kernel-access memory address space and the CPU, and between the GPU buffer in kernel-access memory address space and the GPU, without direct intervention of the CPU. However, to transfer data, for example, from the CPU to the GPU, may result in creating a redundant non-page-locked buffer in user-access memory address space, copying data from the CPU buffer to the user-access buffer, and copying data from the user-access buffer to the GPU buffer. Kernel application programming interfaces (APIs) may include functionality to copy data between kernel-access and user-access buffers.
Various proposed schemes to avoid creation of a redundant non-page-locked buffer during data transfer between devices have included customized hardware support of interconnected devices, or collaboration between device vendors during development of device drivers. These schemes introduce additional disadvantages, such as incompatibility with new devices, and standard hardware interfaces or common device drivers that may drive additional cost and complexity into the development of new devices. As such, apparatus and methods to transfer data between devices that minimizes redundant data copies and latency, while utilizing existing kernel APIs provides significant advantages.
SUMMARY
One exemplary embodiment includes a method to copy data comprising mapping, with kernel permissions, a first virtual memory address to a first physical memory address, mapping, with kernel permissions, a second virtual memory address to a second physical memory address. This embodiment further includes receiving the data at the first physical memory address, mapping, with user permissions, a third virtual memory address to the first physical memory address, and copying, with kernel permissions, the data from the first physical memory address to the second physical memory address.
Another exemplary embodiment includes a system to copy data comprising a memory and a processor, coupled to the memory, configured to map, with kernel permissions, a first virtual memory address to a first physical memory address in the memory. This embodiment includes the processor configured to map, with kernel permissions, a second virtual memory address to a second physical memory address in the memory and receive the data at the first physical memory address. Still further, this embodiment includes the processor configured to map, with user permissions, a third virtual memory address to the first physical memory address, and copy, with kernel permissions, the data from the first physical memory address to the second physical memory address.
An additional exemplary embodiment includes a non-transitory computer readable medium comprising instructions that when executed by a processor cause the processor to map, with kernel permissions, a first virtual memory address to a first physical memory address and map, with kernel permissions, a second virtual memory address to a second physical memory address and receive data at the first physical memory address. This exemplary embodiment also includes the non-transitory computer readable medium comprising instructions that when executed by a processor cause the processor to map, with user permissions, a third virtual memory address to the first physical memory address, and copy, with kernel permissions, the data from the first physical memory address to the second physical memory address.
The above exemplary embodiments will become more readily apparent from the following detailed description with reference to the accompanying drawings. However, the above exemplary embodiments do not limit additional disclosed embodiments present in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
Embodiments of the disclosure are described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left most digit(s) of a reference number identifies the drawing in which the reference number first appears.
FIG. 1 illustrates a block diagram of a computing system comprising multiple DMA device interfaces according to an exemplary embodiment of the present disclosure;
FIG. 2 illustrates a block diagram of a computing system comprising a shared memory partitioned into user and kernel access memory address spaces according to an exemplary embodiment of the present disclosure;
FIG. 3 illustrates a block diagram of a memory system including two device interfaces according to an exemplary embodiment of the present disclosure;
FIG. 4 illustrates a flowchart including operational steps to transfer data between two devices using a shared memory according to an exemplary embodiment of the present disclosure;
FIG. 5 illustrates a block diagram of a memory system including virtual to physical address remapping according to an exemplary embodiment of the present disclosure;
FIG. 6 illustrates a flowchart including operational steps to transfer data between two devices using a shared memory according to an exemplary embodiment of the present disclosure;
FIG. 7 illustrates a block diagram of a memory system including virtual to physical address remapping and copy-on-write according to an exemplary embodiment of the present disclosure; and
FIG. 8 illustrates a flowchart including operational steps to preserve the integrity of copy-on-write device buffers according to an exemplary embodiment of the present disclosure.
Embodiments of the disclosure will now be described with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the reference number.
DETAILED DESCRIPTION
The following Detailed Description refers to accompanying drawings to illustrate exemplary embodiments consistent with the disclosure. References in the Detailed Description to “one exemplary embodiment,” “an exemplary embodiment,” “an example exemplary embodiment,” etc., indicate that the exemplary embodiment described can include a particular feature, structure, or characteristic, but every exemplary embodiment can not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same exemplary embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an exemplary embodiment, it is within the knowledge of those skilled in the relevant art(s) to affect such feature, structure, or characteristic in connection with other exemplary embodiments whether or not explicitly described.
FIG. 1 illustrates a block diagram of a computing system 100 comprising multiple interface devices 110 and 120 , each including a DMA controller 130 and 140 , interfacing with a shared memory 150 . A processor 160 interfaces with the DMA controllers 130 and 140 , and the shared memory 150 . In one embodiment, the processor 160 may execute instructions stored in the memory 150 that cause the processor 160 to configure the DMA controller 130 to transfer data from the interface device 110 to an input buffer 152 in the memory 150 without further intervention from the processor 160 . Likewise, the processor 160 may execute instructions stored in the memory 150 that cause the processor 160 to configure the DMA controller 140 to transfer data from an output buffer 154 in the memory 150 to the interface device 120 without further intervention from the processor 160 .
As such, as data becomes available at the interface device 110 , the DMA controller 130 transfers data from the interface device 110 to the input buffer 152 and the processor 160 may process the data stored therein. When data becomes available in the output buffer 154 , the DMA controller 140 may transfer the data stored therein to the interface device 120 . In some embodiments, to transfer data from the interface device 110 to the interface 120 , the processor 160 may generate an intermediate copy of data stored in the input buffer 152 , and subsequently move the data to the output buffer 154 .
FIG. 2 illustrates a block diagram of a computing system 200 including a shared memory 205 partitioned into a user address space 232 and a kernel address space 222 . The user address space 232 may, in some embodiments, include a range of memory addresses that a process with user-level permissions executing on a processor (not illustrated in FIG. 2 ) may read, write, or modify. Likewise, the kernel address space 222 may, in some embodiments, include a range of memory addresses that a process with kernel-level permissions executing on a processor (not illustrated in FIG. 2 ) may read, write, or modify.
Similar to FIG. 1 , the computing system 200 includes interface devices 210 and 215 , each including respective DMA controllers 225 and 240 . The DMA controller 225 may transfer data from the interface device 210 into an input buffer 220 , page-locked in the kernel address space 222 of the memory 205 . Likewise, the DMA controller 240 may transfer data from an output buffer 235 , page-locked in the kernel address space 222 of the memory 205 to the interface device 215 . As such, a process with kernel-level permissions, executing on a processor (not illustrated in FIG. 2 ), may read, write, or modify the input buffer 220 or output buffer 235 . In some embodiments, the input buffer 220 may be copied to a user buffer 230 in the user address space by a process with user-level permissions executing a kernel API function, such as copy_to_user( ), that spawns or instructs a process with kernel permissions to allocate the user buffer 230 , and copy data from the input buffer 220 to the user buffer 230 . Likewise, the user buffer 230 may be copied to the output buffer 235 by a process with user-level permissions executing a kernel API function, such as copy_from_user( ), that spawns or instructs a process with kernel permissions to copy data from the user buffer 230 to the output buffer 235 . Thus, the memory 205 provides a conduit for data transfer between the interface device 210 and the interface device 215 while maintaining a user/kernel permission separation of the memory 205 .
FIG. 3 illustrates a block diagram of a memory system 300 including a virtual memory address space 310 , a physical memory address space 320 , a page table translator 321 , and interfaces to an input device 347 and an output device 348 through a DMA controller 346 . The virtual memory address space 310 may comprise a plurality of memory addresses that map to a plurality of memory addresses in the physical memory address space 320 . The page table translator 321 may translate a given virtual memory address in the virtual memory address space 310 to a physical memory address in the physical memory address space 320 , and vice versa. Similar to FIG. 2 , the DMA controller 346 may transfer data between the input device 347 and output device 348 and their respective page-locked device buffers 335 and 345 . Each page-locked device buffer 335 and 345 in the physical address space 320 may have a corresponding virtual device buffer 330 and 340 in a kernel-access virtual memory address space 333 of the virtual memory address space 310 . In some embodiments, a process with kernel-level permission running on a processor may read, write, or modify the virtual device buffers 330 and 340 in the kernel-access virtual memory address space 333 of the virtual memory address space 310 .
In one embodiment, the DMA controller 346 transfers data from the input device 347 into a page-locked device buffer 335 in the physical address space 320 . A process with user-level permissions executing on a processor executes a kernel API function, for example, copy_to_user( ), a process with kernel-level permissions may instantiate a non-page-locked buffer 355 in the physical address space 320 . Subsequently, the process with kernel-level permissions may instantiate a virtual user buffer 350 and update the page table translator 321 to indicate that the non-page-locked buffer 355 corresponds to the virtual user buffer 350 . In such an embodiment, the copy_to_user( ) kernel API may further cause a process with kernel-level permissions to copy data from the page-locked device buffer 335 to the non-page-locked buffer 355 . At this point, a process with user-level permissions may read, write, or modify the data contained in the non-page-locked buffer 355 , and the corresponding virtual user buffer 350 . Likewise, the process with user-level permissions may execute a kernel API function, for example, copy_from_user( ), causing a process with kernel-level permissions to copy the data from the non-page-locked buffer 355 to the page-locked device buffer 345 . The DMA controller 346 may transfer the data in the page-locked device buffer 345 to an output device 348 , thus completing the transfer of data from the input device 347 to the output device 348 . In other embodiments, the input device 347 and output device 348 may comprise one device with both input and output capabilities.
FIG. 4 illustrates a flowchart 400 including operational steps to transfer data between two devices using a memory including a kernel address space and a user address space. The flowchart illustrated in FIG. 4 references the exemplary embodiment illustrated in FIGS. 1-3 , however, the exemplary embodiments illustrated in FIGS. 1-3 do not limit the exemplary method steps illustrated in flowchart 400 . Furthermore, the order of method steps illustrated in flowchart 400 , in some embodiments, may execute in alternative orders, or in other embodiments, execute simultaneously while remaining within the scope and spirit of the disclosure.
The flowchart 400 includes step 410 , wherein, in some embodiments, a DMA controller, similar to the DMA controller 346 of FIG. 3 , transfers data directly from a first device, to a first page-locked buffer in a kernel address space. The first device may correspond, in some embodiments, to the input device 347 of FIG. 3 , and the first page-locked buffer may correspond to the non-page-locked device buffer 355 , and the corresponding virtual device buffer 330 in the kernel-access virtual address space 333 .
Step 420 includes, in some embodiments, a process with kernel-level permissions, executing on a processor, copying data from the first page-locked buffer in kernel address space to a non-page-locked buffer in user address space. In a similar embodiment, the process with kernel-level permissions, executing on the processor, at step 430 , copies data from the non-page-locked buffer in user address space to a second page-locked buffer in kernel address space.
The second page-locked buffer in kernel address space in some embodiments, corresponds to the page-locked device buffer 345 , and the corresponding virtual device buffer 340 in the kernel-access virtual address space 333 . Step 440 , includes, in some embodiments, a DMA controller transfers data directly from the second page-locked buffer in kernel address space to a second device. The DMA controller may correspond, for example, to the DMA controller 346 in FIG. 3 . Likewise, the second device may correspond, for example to the output device 348 in FIG. 3 . Thus, the flowchart 400 enables data transfer from the first device to the second device using a memory including a kernel address space and a user address space.
FIG. 5 illustrates a block diagram of a memory system 500 , similar to the memory system 300 in FIG. 3 , including a virtual memory address space 510 , a physical memory address space 520 , a page table translator 521 , and interfaces to an input device 547 and an output device 548 through a DMA controller 546 . The virtual memory address space 510 may comprise a plurality of memory addresses that map to a plurality of memory addresses in the physical memory address space 520 . The page table translator 521 may translate a given virtual memory address in the virtual memory address space 510 to a physical memory address in the physical memory address space 520 , and vice versa. Similar to FIG. 3 , the DMA controller 546 may transfer data between the input device 547 and output device 548 and their respective page-locked device buffers 535 and 545 . Each page-locked device buffer 535 and 545 in the physical address space 520 may have a corresponding virtual device buffer 530 and 540 in a kernel-access portion 533 of the virtual memory address space 510 . In some embodiments, a process with kernel-level permission running on a processor may read, write, or modify the virtual device buffers 530 and 540 in the kernel-access portion 533 of the virtual memory address space 510 .
In one embodiment, the DMA controller 546 transfers data from the input device 547 into a page-locked device buffer 535 in the physical address space 520 . A process with user-level permissions, executes a modified kernel API function, for example, a modified version of copy_to_user( ). The modified version of copy_to_user( ) may spawn or cause a process with kernel-level permissions to instantiate a virtual user buffer 550 in the user-access virtual address space 551 and update the page table translator 521 to indicate that the virtual user buffer 550 also corresponds to the page-locked device buffer 535 . Thus, the page-locked device buffer 535 now has two corresponding buffers, the virtual user buffer 550 in the user-access address space 551 , and the virtual device buffer 530 in kernel address space 533 . The modified version of copy_to_user( ) may for example be included as a configuration option when a driver is linked into the kernel compiler option. In other embodiments, the modified version of copy_to_user( ) may be a compilation option for the kernel itself.
In the above embodiment, in order to preserve the user/kernel access abstraction, the page-locked device buffer 535 may be designated as copy-on-write. A copy-on write designation may indicate that if the page-locked device buffer 535 , or the corresponding virtual user buffer 550 is modified or over-written by a process with user-level access, that the page-locked device buffer 535 be first copied to another physical memory location before modification.
A process with user-access may execute, for example, the copy_from_user( ) kernel API that causes a process with kernel-level permissions to copy data from the page-locked device buffer 535 to the page-locked device buffer 545 . Thus, a similar copy from the page-locked device buffer 535 to the page-locked device buffer 545 occurs without instantiating the non-page-locked buffer 355 of FIG. 3 while maintaining the user/kernel access abstraction. Subsequently, the DMA controller 546 may transfer the data in the page-locked device buffer 545 to an output device 548 , thus completing the transfer of data from the input device 547 to the output device 548 . In other embodiments, the input device 547 and output device 548 may comprise one device with both input and output capabilities.
FIG. 6 illustrates a flowchart 600 including operational steps to transfer data between two devices using a memory including a kernel address space and a user address space. The flowchart illustrated in FIG. 6 references the exemplary embodiment illustrated in FIG. 5 , however, the exemplary embodiment illustrated in FIG. 5 does not limit the exemplary method steps illustrated in flowchart 600 . Furthermore, the order of method steps illustrated in flowchart 600 , in some embodiments, may execute in alternative orders, or in other embodiments, execute simultaneously while remaining within the scope and spirit of the disclosure.
The flowchart 600 includes step 610 , wherein, in some embodiments, a DMA controller, similar to the DMA controller 546 of FIG. 5 , transfers data directly from a first device, to a first page-locked buffer in a kernel address space. The first device may correspond, in some embodiments, to the input device 547 of FIG. 5 , and the first page-locked buffer may correspond to the page-locked device buffer 535 , and the corresponding virtual device buffer 530 in the kernel-access virtual address space 533 .
Step 620 includes, in some embodiments, a process with kernel-level permissions that remaps a virtual user buffer in a page table translator to the first page-locked buffer in kernel address space. In one embodiment, the virtual user buffer corresponds to the virtual user buffer 550 of FIG. 5 , and the page table translator corresponds to the page table translator 521 of FIG. 5 .
Step 640 includes marking the first page-locked buffer in kernel address space copy-on-write. In some embodiments, the copy-on-write indication resides in the page table translator 521 of FIG. 5 . In a similar embodiment, the process with kernel-level permissions, executing on the processor, at step 650 , copies data from the first page-locked buffer to a second page-locked buffer.
The second page-locked buffer in kernel address space in some embodiments, corresponds to the page-locked device buffer 545 and the corresponding virtual device buffer 540 in the kernel-access virtual address space 533 . Step 660 , includes, in some embodiments, a DMA controller transferring data directly from the second page-locked buffer in kernel address space to a second device. The DMA controller may correspond, for example, to the DMA controller 546 in FIG. 5 . Likewise, the second device may correspond, for example to the output device 548 in FIG. 5 . Thus, the flowchart 600 enables data transfer from the first device to the second device that reduces redundant physical memory copies while maintaining the user/kernel access abstraction.
FIG. 7 illustrates a block diagram of a memory system 700 , similar to the memory system 500 in FIG. 5 , including a virtual memory address space 710 , a physical memory address space 720 , a page table translator 721 , and interfaces to an input device 747 and an output device 748 through a DMA controller 746 . The virtual memory address space 710 may comprise a plurality of memory addresses that map to a plurality of memory addresses in the physical memory address space 720 . The page table translator 721 may translate a given virtual memory address in the virtual memory address space 710 to a physical memory address in the physical memory address space 720 , and vice versa. Similar to FIG. 5 , the DMA controller 746 may transfer data between the input device 747 and output device 748 and their respective page-locked device buffers 735 and 745 . Each page-locked device buffer 735 and 745 in the physical address space 720 may have a corresponding virtual device buffer 730 and 740 in a kernel-access portion 733 of the virtual memory address space 710 . In some embodiments, a process with kernel-level permission running on a processor may read, write, or modify the virtual device buffers 730 and 740 in the kernel-access portion 733 of the virtual memory address space 710 .
In one embodiment, the DMA controller 746 transfers data from the input device 747 into a page-locked device buffer 735 in the physical address space 720 . A process with user-level permissions, executes a modified kernel API function, for example, a modified version of copy_to_user( ). The modified version of copy_to_user( ) may spawn or cause a process with kernel-level permissions to instantiate a virtual user buffer 750 in the user-access virtual address space 751 and update the page table translator 721 to indicate that the virtual user buffer 750 also corresponds to the page-locked device buffer 735 . Thus, the page-locked device buffer 735 now has two corresponding buffers, the virtual user buffer 750 in the user-access address space 751 , and the virtual device buffer 730 in kernel address space 733 . The modified version of copy_to_user( ) may for example be included as a configuration option when a driver is linked into the kernel compiler option. In other embodiments, the modified version of copy_to_user( ) may be a compilation option for the kernel itself.
In the above embodiment, in order to preserve the user/kernel access abstraction, the page-locked device buffer 735 may be designated as copy-on-write. A copy-on write designation may indicate that if the page-locked device buffer 735 , or the corresponding virtual user buffer 750 is modified or over-written by a process with user-level access, that the page-locked device buffer 735 be first copied to another physical memory location before modification. When such a modification or over-write occurs by a process with user-access, a process with kernel-access instantiates a non-page-locked buffer 755 and updates the page table translator 721 to indicate that the virtual user buffer 750 corresponds to the non-page-locked buffer 755 . At this point, a process with user-level permissions may read, write, or modify the data contained in the non-page-locked buffer 755 , and the corresponding virtual user buffer 750 .
Similar to the embodiments illustrated in FIGS. 3 and 5 , a process with user-access may execute, for example, the copy_from_user( ) kernel API that causes a process with kernel-level permissions to copy data from the page-locked device buffer 735 to the page-locked device buffer 745 . Thus, a similar copy from the page-locked buffer 735 to the page-locked device buffer 745 occurs without instantiating the non-page-locked buffer 355 of FIG. 3 while maintaining the user/kernel access abstraction. Subsequently, the DMA controller 746 may transfer the data in the page-locked device buffer 745 to an output device 748 , thus completing the transfer of data from the input device 747 to the output device 748 . In other embodiments, the input device 747 and output device 748 may comprise one device with both input and output capabilities.
FIG. 8 illustrates a flowchart 800 including operational steps to preserve the integrity of copy-on-write device buffers using page remapping. The flowchart illustrated in FIG. 8 references the exemplary embodiment illustrated in FIG. 7 , however, the exemplary embodiment illustrated in FIG. 7 does not limit the exemplary method steps illustrated in flowchart 800 . Furthermore, the order of method steps illustrated in flowchart 800 , in some embodiments, may execute in alternative orders, or in other embodiments, execute simultaneously while remaining within the scope and spirit of the disclosure.
The flowchart 800 includes step 810 , wherein, in some embodiments, a process with user-access attempts to modify data in a page-locked buffer marked copy-on-write using a user buffer. As a consequence of attempting to modify data in the page-locked buffer marked copy-on-write, the processor may issue a page fault, for example indicating that the data is unavailable. The page-locked buffer marked copy-on-write may for example correspond to the page-locked device buffer 735 of FIG. 7 and the user buffer may correspond to the virtual user buffer 750 of FIG. 7 .
Step 820 includes, in some embodiments, a process with kernel-level permissions, executing on a processor, copying data from the page-locked buffer in kernel address space to a non-page-locked buffer in user address space. Step 830 includes remapping the user buffer to the non-page-locked device buffer. Thus, a process with user-level permissions may read, write, or modify the data contained in the non-page-locked buffer and the corresponding user buffer.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
CONCLUSION
The exemplary embodiments described herein are provided for illustrative purposes, and are not limiting. Other exemplary embodiments are possible, and modifications may be made to the exemplary embodiments within the spirit and scope of the disclosure. Therefore, the Detailed Description is not meant to limit the disclosure. Rather, the scope of the disclosure is defined only in accordance with the following claims and their equivalents.
Embodiments of the disclosure may be implemented in hardware, firmware, software, or any combination thereof. Embodiments of the disclosure may also be implemented as instructions stored on a machine-readable medium, which may be read and executed by one or more processors. A machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computing device). For example, a machine-readable medium may include read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), and others. Further, firmware, software, routines, instructions may be described herein as performing certain actions. However, it should be appreciated that such descriptions are merely for convenience and that such actions in fact result from computing devices, processors, controllers, or other devices executing the firmware, software, routines, instructions, etc.
It is to be appreciated that the Detailed Description section, and not the Abstract section, is intended to be used to interpret the claims. The Abstract section may set forth one or more, but not all exemplary embodiments, of the disclosure, and thus, are not intended to limit the disclosure and the appended claims in any way.
The disclosure has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries may be defined so long as the specified functions and relationships thereof are appropriately performed.
It will be apparent to those skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the disclosure. Thus the disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | Central processing units (CPUs) in computing systems manage graphics processing units (GPUs), network processors, security co-processors, and other data heavy devices as buffered peripherals using device drivers. Unfortunately, as a result of large and latency-sensitive data transfers between CPUs and these external devices, and memory partitioned into kernel-access and user-access spaces, these schemes to manage peripherals may introduce latency and memory use inefficiencies. Proposed are schemes to reduce latency and redundant memory copies using virtual to physical page remapping while maintaining user/kernel level access abstractions. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an equalizing circuit for reducing surface roughness of an image and a method thereof, and an image processing circuit and a method by the use of the equalizing circuit and its method.
[0002] Conventionally, for example, Jpn. Pat. Appln Publication No. 8-18777 discloses an art with respect to an image processing unit, which improves a resolution of a character part of an image represented by the input image data and improves a gradation of a picture part thereof. That is, according to this art, a character region and a photographic region of an original document are separated and a region signal is output. Then, in accordance with this region signal, gradation processing results for a character and a photograph are selectively switched.
[0003] However, in the above described conventional art, it is not suggested to equalize the image signals of the original document in increments of an arbitrary block from an arbitrary position. Further, it is not specifically disclosed to reduce the surface roughness of the image.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention has been made taking the problems into consideration and an object of which is as follows. More specifically, according to the present invention, an input image data signal is equalized in increments of an arbitrary matrix from an arbitrary starting position, in other words, an input image data signal is equalized in increments of a certain equalized block. Then, respective input image data signal in the equalized block is replaced with the equalized image data to be output. Hereby, the surface roughness is reduced.
[0005] In order to attain the above described object, an equalizing circuit according to a first aspect of the present invention comprises a memory control unit which receives an input of an input image data signal; a register setting unit which receives setting of a main scan coordinate and a subscan coordinate to start at least the equalizing of the input image data signal; an equalizing control unit which starts the equalizing of the input image data signal from the main scan coordinate and the subscan coordinate, which are set by the register setting unit, and outputs the equalized image data signal; and an output control unit which receives an input of an equalized image data signal from the equalizing control unit and outputs it as an output image data signal.
[0006] Alternatively, an image processing circuit according to a second aspect of the present invention comprises a memory control unit which receives an input of an input image data signal; a first memory which stores the input image data signal after delaying it; a CPU which designates at least any one of a main scan coordinate and a subscan coordinate to start equalizing of the input image data signal, a main scan size and a subscan size of the equalized block and skew values in a main scan direction and in a subscan direction of the equalized block; a register setting unit which holds the setting information which is designated by the CPU; an equalizing control unit which performs the equalizing of the input image data signal at a certain timing independently of a skew value of the equalized block on the basis of the setting information held by the register setting unit and outputs the equalized image data signal; a second memory which receives an input of the equalized image data signal from the equalizing control unit and holds it as an output image data signal; and an output control unit which outputs the output image data of the second memory.
[0007] Alternatively, an equalizing method according to a third aspect of the present invention comprises receiving an input of an input image data signal from a memory control unit; receiving setting of a main scan coordinate and a subscan coordinate to start at least the equalizing of the input image data signal by a register setting unit; starting the equalizing of the input image data signal from the main scan coordinate and the subscan coordinate, which are set by the register setting unit, and outputting the equalized image data signal by an equalizing control unit; and receiving an input of the equalized image data signal and outputting it as an output image data signal by an output control unit.
[0008] Alternatively, an image processing method according to a fourth aspect of the present invention comprises receiving an input of an input image data signal by a memory control unit; storing the input image data signal after delaying it by a first memory; designating at least any one of a main scan coordinate and a subscan coordinate to start equalizing of the input image data signal, a main scan size and a subscan size of the equalized block and skew values in a main scan direction and in a subscan direction of the equalized block by a CPU; holding the setting information which is designated by the CPU at a register setting unit; performing the equalizing of the input image data signal at a certain timing independently of a skew value of the equalized block on the basis of the setting information held by the register setting unit and outputting the equalized image data signal by an equalizing control unit; receiving an input of the equalized image data signal from the equalizing control unit and holding it as an output image data signal by a second memory; and outputting the output image data of the second memory by an output control unit.
[0009] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
[0011] [0011]FIGS. 1A and 1B are views for explaining an outline of the processing according to an equalizing circuit to be employed for an image processing circuit according to an embodiment of the present invention;
[0012] [0012]FIG. 2A is a view for illustrating a concept of the processing 1 (without a skew) and FIG. 2B is a view for illustrating a concept of the processing 1 (with a skew);
[0013] [0013]FIG. 3A is a view for illustrating a concept of the processing 2 (a left end in the image), FIG. 3B is a view for illustrating a concept of the processing 3 (a right end in the image), FIG. 3C is a view for illustrating a concept of the processing 4 (an upper end in the image) and FIG. 3D is a view for illustrating a concept of the processing 5 (a lower end in the image);
[0014] [0014]FIG. 4 is a view for illustrating an image of the equalizing processing with respect to the image data having M pixels in a main scan direction and N lines in a subscan direction;
[0015] [0015]FIG. 5 is a view for illustrating a constitution of an equalizing circuit as an image processing circuit according to an embodiment of the present invention and a constitution of its peripheral circuit;
[0016] [0016]FIG. 6A is a view for illustrating a relation between a line delay memories 11 ( 1 ) . . . 11 (n−1) and an input image data signal and FIG. 6B is a timing chart for illustrating a relation between the line delay memories 11 ( 1 ) . . . 11 (n−1) and the input image data signal;
[0017] [0017]FIG. 7 is a view for illustrating a detailed constitution of an equalizing control unit 3 ;
[0018] [0018]FIG. 8 is a view for illustrating a detailed constitution of an equalized matrix generating/calculating unit 21 ;
[0019] [0019]FIG. 9A is a conceptual diagram of the equalizing process when there is no skew (a grid shape) and FIG. 9B is a timing chart according to the equalizing process when there is no skew (a grid shape);
[0020] [0020]FIGS. 10A and 10B are conceptual diagrams of the calculation process when there is no skew (a grid shape) and FIG. 10C is a timing chart according to the calculation process when there is no skew (a grid shape);
[0021] [0021]FIG. 11 is a view for illustrating respective setting values;
[0022] [0022]FIG. 12 is a view for explaining a process for processing one page image by an equalizing circuit to be employed in an image processing circuit according to an embodiment of the present invention;
[0023] [0023]FIG. 13 is a view for illustrating a constitution of a modified example such that a plurality of equalizing circuits to be employed for an embodiment of the present invention are used depending on an application for a photograph and a character or the like;
[0024] [0024]FIG. 14 is a view for illustrating an image of the processing when the adjustment according to the embodiment is not performed and an equalized matrix comprises a matrix of 6×3;
[0025] [0025]FIG. 15 is a timing chart of the processing when the adjustment according to the embodiment is not performed and an equalized matrix comprises a matrix of 6×3;
[0026] [0026]FIG. 16 is a view for illustrating an image of the processing when the adjustment according to the embodiment is not performed and an equalized matrix comprises a matrix of 4×3;
[0027] [0027]FIG. 17 is a timing chart of the processing when the adjustment according to the embodiment is not performed and an equalized matrix comprises a matrix of 6×3;
[0028] [0028]FIG. 18 is a view for illustrating an image of the processing when the adjustment according to the embodiment is performed and an equalized matrix comprises a matrix of 6×3;
[0029] [0029]FIG. 19 is a timing chart of the processing when the adjustment according to the embodiment is performed and an equalized matrix comprises a matrix of 6×3;
[0030] [0030]FIG. 20 is a view for illustrating an image of the processing when the adjustment according to the embodiment is performed and an equalized matrix comprises a matrix of 4×3;
[0031] [0031]FIG. 21 is a timing chart is a timing chart of the processing when the adjustment according to the embodiment is performed and an equalized matrix comprises a matrix of 6×3;
[0032] [0032]FIG. 22 is a constitutional view of an image processing circuit, in which a plurality of equalizing circuits capable of setting two sorts of equalized matrices, i.e., 4×3 and 6×3; and
[0033] [0033]FIG. 23 is a constitutional view of an image processing circuit capable of setting two sorts of equalized matrices, i.e., 4×3 and 6×3 by a single equalizing circuit.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Embodiments according to the present invention will be explained with reference to the drawings below.
[0035] At first, with reference to FIG. 1A and FIG. 1B, an outline of the processing according to an equalizing circuit to be employed for an image processing circuit according to an embodiment of the present invention will be explained.
[0036] The equalizing circuit according to this embodiment carries out the equalization with respect to an input image data signal by an equalized block defined by a matrix of m×n (m, n is an arbitrary integer number) comprising m pixels (hereinafter, referred to as a main scan size) in a main scan direction and n lines (hereinafter, referred to as a subscan size) in a subscan direction. For example, in FIG. 1A, the equalized block defined by a matrix of 4×3.
[0037] Then, for example, a result of the equalizing processing with respect to the input image data signal shown in FIG. 1A is shown in FIG. 1B. That is, as shown in FIG. 1B, a value of the equalized pixel is defined as a value obtained by dividing sum of the pixels in an equalized block with the number of pixels in the equalized block.
[0038] For example, AV 00 in FIG. 1B is defined as AV 00 ={(D 00 +D 01 +D 02 +D 03 )+(D 10 +D 11 +D 12 +D 13 )+(D 20 +D 21 +D 22 +D 23 )}/4×3.
[0039] In this way, according to the embodiment, the rough surface of the image is reduced by outputting an arbitrary intended pixel as an average value of the peripheral pixels. Further, according to the embodiment, the equalized block according to the equalizing process can be varied to an arbitrary size. Hereby, it is possible to perform the equalizing process depending on the sorts of the input image data signals.
[0040] Next, with reference to FIGS. 2A and 2B and FIGS. 3A and 3D, the equalizing process of an equalizing circuit to be employed in an image processing circuit according to an embodiment will be described in detail below.
[0041] In FIGS. 2A and 2B, a starting position of equalizing process is a left upper end of an input image data, namely, a phase of an equalized block is “0” in both of a main scan direction and a subscan direction.
[0042] According to the embodiment, it is assumed that the equalizing process is performed in increments of an equalized block which is defined by a matrix of 4×3 in four pixels in a main scan direction and three lines in a subscan direction.
[0043] For more details, FIG. 2A illustrates a case that the equalizing process in a grid shape is performed (there is no skew of the equalized block) and FIG. 2B illustrates a case that the equalizing process in an angled shape is performed (a phase of the equalized block is set).
[0044] The above described embodiment gives an example of a normal equalized process.
[0045] On the contrary, FIGS. 3A to 3 D illustrate examples of the process at a left end, a right end, an upper end and a lower end of an image (hereinafter referred to as a process outside of the region).
[0046] That is, FIG. 3A illustrates an example such that a phase in a main scan direction is set as “2” and a phase in a subscan direction is set as “0”. Additionally, FIG. 3C illustrates an example such that a phase in a main scan direction is set as “0” and a phase in a subscan direction is set as “2”. In these cases, a skew of an equalized block is not set.
[0047] Alternatively, FIGS. 3B and 3D illustrate examples such that a termination position of the equalizing is located at a right end or a lower end of an image. These processes outside of a region is realized, for example, by through-outputting an original input image data at an upper end and a lower end of the image and, for example, by equalizing the image data by the use of edge pixels at a left end and a right end of the image.
[0048] Alternatively, in the following explanation, a normal process shown in FIG. 2A and FIG. 2B is defined as a process 1 and the processes outside of the region shown in FIGS. 3A to 3 D are defined as the processes 2 to 5 , respectively.
[0049] Next, FIG. 4 illustrates an image of the equalizing with respect to the image data having M pixels in a main scan direction and N lines in a subscan direction.
[0050] According to this example, a size of an equalized block is defined as 6×3.
[0051] In FIG. 4, a process 4 , a process 2 , a process 3 (it is limited to the case that the process is outside of the region), a process 5 and a normal process 1 are performed, respectively, at the upper end of the image, at the right end of the image, at the left end of the image, at the lower end of the image and within the region.
[0052] The details of respective processes 1 to 5 are as already mentioned.
[0053] Next, FIG. 5 illustrates a constitution of an equalizing circuit as an image processing circuit according to an embodiment of the present invention and a constitution of its peripheral circuit.
[0054] As shown in FIG. 5, this equalizing circuit 10 comprises a memory control unit 1 , a register setting unit 2 , an equalizing control unit 3 and an output control unit 4 .
[0055] This memory control unit 1 is connected to memories 11 ( 1 ) . . . 11 (n−1) and the equalizing control unit 3 in such a manner that they can be communicating with the memories 11 ( 1 ) . . . 11 (n−1) and the equalizing control unit 3 . In this case, a reference numeral n means a size of an equalized matrix block in a subscan direction.
[0056] Further, this memory control unit 1 receives an input image data signal, an input subscan directional image effective signal and an input main scan directional image effective signal from the outside.
[0057] Then, as shown in FIG. 6A, this memory control unit 1 accumulates the present input image data signals in the memories 11 ( 1 ) to 11 (n−1). Further, on the basis of the input subscan directional image effective signal and the input main scan directional image effective signal, the memory control unit 1 generates the delay image data signals from one line to (n−1) line, which are delayed line by line, and outputs them to the equalizing control unit 3 .
[0058] That is, for more details, as shown in FIG. 6B, the memory control unit 1 accumulates the image data, which are delayed clock by clock for every time that the input main scan image effective signal turns from “H” to “L” and it returns to “H”, in respective memories 11 ( 1 ) to 11 (n−1) in an output term of one page that the input subscan image effective signal turns from “H” to “L” and it returns to “H”. Then, the memory control unit 1 reads out the image data delay signals from one line to (n−1) line from the present memories 11 ( 1 ) to 11 (n−1) to output them to the equalizing control unit 3 .
[0059] In this case, the detailed constitution of the above described equalizing control unit 3 is shown in FIG. 7.
[0060] That is, for more details, as shown in FIG. 7, the equalizing control unit 3 has a memory control signal generating unit 20 , an equalized matrix block generating/calculating unit 21 , an equalized data/control signal delay adjusting unit 22 , a setting value count/mode generating unit 23 , an equalized clock generating unit 24 and an output control signal generating unit 25 .
[0061] According to such a constitution, an equalizing start main scan coordinate, an equalizing start subscan coordinate, an equalized block main scan directional skew value, an equalized block subscan directional skew value, which are output from the register setting unit 2 by the control by an outside CPU 12 , are transmitted to the setting value count/mode generating unit 23 . Then, the setting value count/mode generating unit 23 generates a mode setting signal, an X size count value signal and an Y size count value signal. This mode setting signal is transmitted to the equalizing matrix generating/calculating unit 21 and the equalizing data/control signal delay adjusting unit 22 .
[0062] Alternatively, the X size count value signal and the Y size count value signal are transmitted to the equalized clock generating unit 24 . Then, the equalized clock generating unit 24 generates a main scan directional equalized clock signal and a subscan directional equalized clock signal and these signals are transmitted to the equalizing matrix generating/calculating unit 21 .
[0063] In this case, a detailed constitution of this equalizing matrix generating/calculating unit 21 is shown in FIG. 8. That is, for more details, this equalizing matrix generating/calculating unit 21 in the equalizing control unit 3 comprises a plurality of flip-flops (F/F), adder 31 , 31 - 1 . . . 31 -(n−1), 33 , a divider 34 and a multiplier 32 .
[0064] According to such a constitution, the adder 31 adds a value of each pixel on the basis of a present line image data signal and the adder 31 - 1 adds a value of each pixel on the basis of one line image data signal. In the same way, the adder 31 -(n−1) adds a value of each pixel on the basis of an n−1 line image data signal.
[0065] Thus, respective obtained added values are further added by the adder 33 , the calculation by the use of a main scan size m of the equalized block and a subscan size n of the equalized block by the means of the multiplier 32 and the divider 34 , so that an equalized image data signal is generated.
[0066] In this way, respective line image data delay signals are input to the equalizing control unit 3 , the equalized matrix block generating/calculating unit 21 generates in this equalizing control unit 3 generates an equalized block. Further, the equalizing has been performed, with the result that an equalized image data signal is generated to be output. In this case, a size of the equalized block is equivalent to a size, which the CPU 12 sets with respect to the register setting unit 2 . That is, a size of the equalized block is set on the basis of a mode setting signal, which is generated by the setting value count/mode generating unit 23 . Alternatively, the equalizing is performed at a timing such that both of the main scan directional equalized clock signal and the subscan directional equalized clock signal, which are generated by the equalized clock generating unit 24 , are “H”.
[0067] Further, the above described mode setting signal, the n−1 line delay subscan directional image effective signal, the input main scan directional image effective signal and the equalized image data signal are transmitted to the equalized data/control signal delay adjusting unit 22 . This equalized data/control signal delay adjusting unit 22 generates an equalized subscan directional image effective signal and an equalized main scan image effective signal on the basis of these signals and outputs them to the output control unit 4 and the output control signal generating unit 25 .
[0068] This output control signal generating unit 25 receives an input of the subscan directional equalized clock signal in addition to the above described signals and generates an output control signal on the basis of these signals.
[0069] Alternatively, an input subscan directional equalized clock signal, an input main scan directional equalized clock signal and an input image data signal are input in the memory control signal generating unit 20 . Then, the memory control signal generating unit 20 generates a memory control signal on the basis of these signals. Further, this memory control signal is feedback to the memory control unit 1 .
[0070] On the other hand, the output control signal, the equalized subscan directional image effective signal, the equalized main scan directional image effective signal and the equalized image data signal each are transmitted to the output control unit 4 .
[0071] While accumulating this equalized image data signal in an outside memory 13 for outputting, this output control unit 4 outputs it as an output image data signal at a timing which is decided on the basis of the output subscan directional image effective signal and the output main scan directional image effective signal.
[0072] With reference to FIGS. 9A, 9B, 10 A to 10 C, the equalizing by the use of the equalizing circuit according to the embodiment will be described more specifically below.
[0073] At first, FIG. 9A illustrates a conceptual diagram of the equalizing when there is no skew (a grid shape) and FIG. 9B illustrates a timing chart according to the process.
[0074] That is, the input image data signal is shown in a center diagram of FIG. 9A, the subscan directional image effective signal is shown in an upper diagram of FIG. 9A and the main scan directional image effective signal is shown in a right diagram of FIG. 9A.
[0075] As shown in FIG. 9A, when there is no skew of the equalized block, the equalizing is performed at a timing such that both of the main scan directional equalized clock signal and the subscan directional equalized clock signal are “H”.
[0076] Alternatively, according to the embodiment, an equalizing calculation process position in the above equalizing process is shown in the central diagram of FIG. 9A in a small rectangular.
[0077] The above described calculation process will be described in more detail with reference to a timing chart shown in FIG. 9B below. After the input subscan directional image effective signal turns from “H” to “L”, the input image data signals have been taken in till the input main scan directional image effective signal turns from “H” to “L” and it returns to “H”. Then, if both of the main scan directional equalized clock signal and the subscan directional equalized clock signal are “H”, the equalized calculation timing signal becomes “H”, so that the equalizing is performed.
[0078] Next, FIG. 10A and FIG. 10B illustrate a conceptual diagrams of the calculation process when there is no skew (a grid shape) and FIG. 10C is a timing chart according to the present calculation process. That is, central diagrams of FIG. 10A and FIG. 10B show the input image data signal, the upper diagrams show the subscan directional equalized clock signal and the right diagrams show the main scan directional equalized clock signal.
[0079] As is obvious from FIG. 10A, when there is a skew of the equalized block, a timing such that the main scan directional equalized clock signal is “H” is not unified by a line. In view of these points, according to the embodiment, as shown in FIG. 10B, the main scan directional equalized clock signals are adjusted so that they become “H” at the same timing. Specifically, the input image data signal and the main scan directional image effective signal are delayed and the equalizing is performed.
[0080] The above described calculation process will be described in more detail with reference to a timing chart shown in FIG. 10C below. After the input subscan directional image effective signal turns from “H” to “L”, the input image data signals have been taken in till the input main scan directional image effective signal turns from “H” to “L” and it returns to “H”. Then, if both of the main scan directional equalized clock signal and the subscan directional equalized clock signal are “H”, the equalized calculation timing signal becomes “H”, so that the equalizing is performed.
[0081] However, according to the embodiment, a skew due to delay of two pixels exists depending on a line. Therefore, an input image data signal is taken in on the basis of the input main scan directional image effective signal, of which two pixels are delayed, with respect to the first to third lines in which the skew exists. The equalizing calculation process is performed on the basis of this taken input image data signal. With respect to the fourth to sixth lines, there is no skew, so that the input main scan directional image effective signal and the input image data signal are used as they are and a normal process is performed.
[0082] Alternatively, a predetermined delay is realized depending on a mode setting signal which is generated by the setting value count/mode generating unit 23 , with the result that an equalized image data signal and an equalized main scan directional image effective signal are generated. The equalizing control unit 3 outputs this equalized image data signal. Alternatively, the above mode setting signal is generated in the register setting unit 2 on the basis of a skew value to be set by the outside CPU 12 .
[0083] In this way, the output control unit 4 writes the equalized image data signal in the output memory 13 for outputting for each subscan size line of the equalized block (i.e., for each line in which the subscan directional equalized clock signal to be output from the equalized clock generating unit 24 in the equalizing control unit 3 is “H”). Then, the output control unit 4 appropriately reads out the equalized image data signal and it is output to the outside as an input image data signal.
[0084] With reference to FIG. 11, each setting values will be explained below.
[0085] In FIG. 11, an equalizing start position means a position plotted by a black circle. In this first embodiment, it is possible to arbitrarily set the equalizing start position.
[0086] Further, an equalized block is defined as a matrix of a main scan size of the equalized block x a subscan size of the equalized block. According to this example, since the equalized block is defined as 6×3, an X size count value is defined in the range of 0 to 5 and a Y size count value is defined in the range of 0 to 2. An X size count initial value is defined as a first pixel on a first line of each block, which is represented by a rectangular in FIG. 11. An equalizing start main scan coordinate and an equalizing start subscan coordinate are allocated to respective pixels, so that they can be specified.
[0087] In addition to these, an equalized block main scan directional skew value and an equalized block subscan directional skew value are defined as shown in the drawing.
[0088] Next, with reference to FIG. 12, a process for processing one page image by an equalizing circuit to be employed in an image processing circuit according to an embodiment will be explained below.
[0089] As shown in this FIG. 12, in this example, it is assumed that the equalized block is defined as a matrix of 6×3, so that a subscan directional equalized clock signal becomes “H” for every three lines and a main scan directional equalized clock signal becomes “H” for every six pixels. Then, the delay of an input main scan directional image effective signal is adjusted by a mode setting signal for each line to be processed, so that an input main scan directional image effective signal which is delayed by one pixel and an input main scan directional image effective signal which is delayed by four pixels or the like are generated.
[0090] According to the present example, the image data at the upper end is through-output on the basis of the process 4 , the image data at the lower end is through-output on the basis of the process 5 . The image data at the left end (D 0 ) performs the equalizing on the basis of the process 2 and the image data at the right end (D 19 ) performs the equalizing on the basis of the process 3 .
[0091] As shown in FIG. 13, when a plurality of equalizing circuits to be employed for an embodiment of the present invention are used depending on an application for a photograph and a character or the like, it is possible to perform the equalizing suitable for sorts of an input image. In this case, respective outputs of a plurality of equalizing circuits 10 - 1 , 10 - 2 , . . . 10 -N (an output subscan directional image effective signal, an output main scan directional image effective signal and an output image data signal) are selected as a negative (−) by a selecting circuit 40 to be output. In this case, an input image identification signal identifies the type among a photograph and a character or the like to which the image belongs.
[0092] As mentioned above, according to this embodiment, when there is a skew of the equalized block, considering that timing, at which the main scan directional equalized clock signal becomes “H”, is not unified by a line, the main scan directional equalized clock signals are adjusted so that they become “H” at the same timing and the image data signal and the main scan directional image effective signal are delayed, so that the equalizing calculation is performed. It will be described in more detail below how to perform the equalizing calculation according to the above described series of processes.
[0093] At first, FIGS. 14 to 17 illustrate an example of the equalizing calculation process when the main scan directional equalized clock signals as shown in the embodiment are not adjusted so that they become “H” at the same timing and its flow will be described in detail below.
[0094] That is, FIG. 14 illustrates an image of the process when an equalized matrix is defined as 6×3 and FIG. 15 shows a timing chart of the process.
[0095] In this case, although there is no skew in first to third lines, in fourth to sixth lines, there is one skew in the main scan direction, in seventh to ninth lines, there are two skews in the main scan direction, in tenth to twelfth lines, there are three skews in the main scan direction, in thirteenth to fifteenth lines, there are four skews in the main scan direction and in fifteenth to eighteenth lines, there are five skews in the main scan direction. Then, there are such skews, with the result that, as shown in FIG. 15 and as being obvious from the main scan directional equalized clock signal, the timing of the equalizing calculation is different depending on a line.
[0096] In the same way, FIG. 16 illustrates an image of the process when an equalized matrix is defined as 4×3 and FIG. 17 shows a timing chart of the process.
[0097] In this case, although there is no skew in first to third lines, in fourth to sixth lines, there is one skew in the main scan direction, in seventh to ninth lines, there are two skews in the main scan direction, in tenth to twelfth lines and there are three skews in the main scan direction.
[0098] Then, there are such skews, with the result that, as shown in FIG. 17 and as being obvious from the main scan directional equalized clock signal, the timing of the equalizing calculation is different depending on a line.
[0099] Conversely, FIGS. 18 to 21 illustrate an example of the equalizing calculation when the adjustment according to the embodiment is performed and its flow will be described in detail below.
[0100] At first, FIG. 18 illustrates an image when an equalized matrix comprises a matrix of 6×3 and FIG. 19 shows a timing chart of the process.
[0101] That is, as shown in this FIG. 18, although there is no skew in first to third lines, in fourth to sixth lines, there is one skew in the main scan direction, in seventh to ninth lines, there are two skews in the main scan direction, in tenth to twelfth lines, there are three skews in the main scan direction, in thirteenth to fifteenth lines, there are four skews in the main scan direction and in fifteenth to eighteenth lines, there are five skews in the main scan direction.
[0102] Therefore, as shown in FIG. 19, the input subscan image effective signal is delayed by six clocks. Then, in the fourth to sixth lines, the main scan directional image effective signal is delayed by one clock, in the seventh to ninth lines, the main scan directional image effective signal is delayed by two clocks, in the tenth to twelfth lines, the main scan directional image effective signal is delayed by three clocks, in the thirteenth to fifteenth lines, the main scan directional image effective signal is delayed by four clocks and in the fifteenth to eighteenth lines, the main scan directional image effective signal respectively is delayed by five clocks.
[0103] In this way, by adjusting the delay for each line to be equalized, the timing of equalizing is unified with respect to all lines.
[0104] In the same way, FIG. 20 illustrates an image when an equalized matrix comprises a matrix of 4×3 and FIG. 21 shows a timing chart of the processing.
[0105] That is, according to this example, as shown in FIG. 20, in fourth to sixth lines, there is one skew in the main scan direction, in seventh to ninth lines, there are two skews in the main scan direction and in tenth to twelfth lines, there are three skews in the main scan direction.
[0106] Therefore, as shown in FIG. 21, the input subscan image effective signal is delayed by six clocks. Then, in the fourth to sixth lines, the main scan directional image effective signal is delayed by one clock, in the seventh to ninth lines, the main scan directional image effective signal is delayed by two clocks and in the tenth to twelfth lines, the main scan directional image effective signal is delayed by three clocks, respectively. Also in this case, by adjusting the delay for each line to be equalized, the timing of equalizing is unified with respect to all lines.
[0107] Alternatively, a predetermined delay process is performed in accordance with a mode setting signal to be generated by the setting value count/mode generating unit 23 in the equalizing control unit 3 , with the result that the above described main scan directional image effective signal is generated.
[0108] In this case, in order to enable a plurality of equalized matrices to be set, it is necessary to provide a plurality of equalized matrix block generating/calculating units 21 .
[0109] For example, in order to enable two sorts of equalized matrices, i.e., 4×3 and 6×3 to be set, a constitution shown in FIG. 22 are employed.
[0110] According to this constitution shown in FIG. 22, an equalized matrix block generating/calculating unit 21 a in accordance with the equalized matrix of 4×3 and an equalized matrix block generating/calculating unit 21 b in accordance with the equalized matrix of 6×3 are provided, so that a selecting unit 50 outputs one of these outputs as an equalized image data signal.
[0111] Alternatively, the details of each of the equalized matrix block generating/calculating unit 21 a and 21 b are the same as those in FIG. 8 basically, so that the explanation thereof is not repeated here.
[0112] In place of the above mentioned constitutions, according to an embodiment of the present invention, an equalized matrix block generating/calculating unit 60 as shown in FIG. 23 can be employed.
[0113] That is, an adder 63 adds a value of each pixel on the basis of image data signal at a present line and an adder 63 - 1 adds a value of each pixel on the basis of the image data signal at a line delayed by one line. In the same way, an adder 63 - 2 adds a value of each pixel on the basis of the image data signal at a line delayed by two lines. In this time, the mode setting signal selects between 6×3 or 4×3 for the equalized block sizes. That is, a plurality of equalized matrix block generating/calculating circuits in accordance with each equalized block size as a constitution shown in FIG. 22 are not provided but one circuit is substitutable.
[0114] An adder 64 further adds respective additional values which are obtained in this way and a multiplier 62 and a divider 65 calculates by the use of the equalized block main scan size and the equalized block subscan size so as to generate an equalized image data signal.
[0115] As mentioned in detail above, according to the embodiment of the present invention, the following effects will be realized.
[0116] That is, according to the embodiment of the present invention, it is possible to arbitrarily set a subscan position and a main scan position for starting the equalizing of the input image data signal. More specifically, it is possible to set a phase of a block to be equalized. Further, it is also possible to set a block size for equalizing the image data signal as an arbitrary size.
[0117] Alternatively, a skew in the equalized block of the input image data signal can be set and the equalizing can be performed both in a grid shape and an angled shape.
[0118] Further, according to the embodiment of the present invention, it is possible to use the equalized matrix block generating/calculating unit in common independently of a size of the equalized block, so that a size of a circuit can be reduced. Then, it becomes possible to perform the equalizing calculation process at certain timing independently of a skew of the equalized block. In addition to them, by using a plurality of equalizing circuits according to the embodiment of the present invention, it is certain that the equalizing depending on the type of the input image data (i.e., a photograph and a character or the like) can be performed.
[0119] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | According to an equalizing circuit and an equalizing method, a memory control unit receives an input of an input image data signal, a first memory stores the input image data signal after delaying it and a CPU designates at least any one of a main scan coordinate and a subscan coordinate to start equalizing of the input image data signal, a main scan size and a subscan size of the equalized block and skew values in a main scan direction and in a subscan direction of the equalized block. Then, a register setting unit holds the setting information which is designated by the CPU and an equalizing control unit performs the equalizing of the input image data signal at a certain timing independently of a skew value of the equalized block on the basis of the setting information held by the register setting unit and outputs the equalized image data signal. Thus, a second memory receives an input of the equalized image data signal from the equalizing control unit and holds it as an output image data signal and an output control unit outputs the output image data of the second memory. | 6 |
This application claims the benefit of the Patent Korean Application No. 10-2005-0019182, filed on Mar. 8, 2005, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an organic electroluminescence device, and more particularly, to red phosphorescene compounds and organic electroluminescence device using the same. Most particularly, the present invention relates to red phosphorescence being used as a dopant of a light emitting layer of an organic electroluminescence device, which is formed by serially depositing an anode, a hole injecting layer, a hole transport layer, a light emitting layer, an electron transport layer, an electron injecting layer, and a cathode.
2. Discussion of the Related Art
Recently, as the size of display devices is becoming larger, the request for flat display devices that occupy lesser space is becoming more in demand. Such flat display devices include organic electroluminescence devices, which are also referred to as an organic light emitting diode (OLED). Technology of such organic electroluminescence devices is being developed at a vast rate and various prototypes have already been disclosed.
The organic electroluminescence device emits light when electric charge is injected into an organic layer, which is formed between an electron injecting electrode (cathode) and a hole injecting electrode (anode). More specifically, light is emitted when an electron and a hole form a pair and the newly created electron-hole pair decays. The organic electroluminescence device can be formed on a flexible transparent substrate such as plastic. The organic electro-luminescence device can also be driven under a voltage lower than the voltage required in a plasma display panel or an inorganic electroluminescence (EL) display (i.e., a voltage lower than or equal to 10V). The organic electroluminescence device is advantageous in that it consumes less energy as compared to other display devices and that it provides excellent color representation. Moreover, since the organic EL device can reproduce pictures by using three colors (i.e., green, blue, and red), the organic EL device is widely acknowledged as a next generation color display device that can reproduce vivid images.
The process of fabricating such organic electroluminescence (EL) device will be described as follows:
(1) An anode material is coated over a transparent substrate. Generally, indium tin oxide (ITO) is used as the anode material. (2) A hole injecting layer (HIL) is deposited on the anode material. The hole injecting layer is formed of a copper phthalocyanine (CuPc) layer having a thickness of 10 nanometers (nm) to 30 nanometers (nm). (3) A hole transport layer (HTL) is then deposited. The hole transport layer is mostly formed of 4,4′-bis[N-(1-naphtyl)-N-phenylamino]-biphenyl (NPB), which is treated with vacuum evaporation and then coated to have a thickness of 30 nanometers (nm) to 60 nanometers (nm). (4) Thereafter, an organic light emitting layer is formed. At this point, a dopant may be added if required. In case of green emission, the organic light emitting layer is generally formed of tris(8-hydroxy-quinolate)aluminum (Alq 3 ) which is vacuum evaporated to have a thickness of 30 nanometers (nm) to 60 nanometers (nm). And, MQD(N-Methylquinacridone) is used as the dopant (or impurity). (5) Either an electron transport layer (ETL) and an electron injecting layer (EIL) are sequentially formed on the organic emitting layer, or an electron injecting/transport layer is formed on the organic light emitting layer. In case of green emission, the Alq 3 of step (4) has excellent electron transport ability. Therefore, the electron injecting and transport layers are not necessarily required. (6) Finally, a layer cathode is coated, and a protective layer is coated over the entire structure.
A light emitting device emitting (or representing) the colors of blue, green, and red, respectively, is decided in accordance with the method of forming the light emitting layer in the above-described structure. As the light emitting material, an exciton is formed by a recombination of an electron and a hole, which are injected from each of the electrodes. A singlet exciton emits fluorescent light, and a triplet exciton emits phosphorescene light. The singlet exciton emitting fluorescent light has a 25% probability of formation, whereas the triplet exciton emitting phosphorescene light has a 75% probability of formation. Therefore, the triplet exciton provides greater light emitting efficiency as compared to the singlet exciton. Among such phosphorescene materials, red phosphorescence material may have greater light emitting efficiency than fluorescent materials. And so, the red phosphorescene material is being researched and studied as an important factor for enhancing the efficiency of the organic electroluminescence device.
When using such phosphorescene materials, high light emitting efficiency, high color purity, and extended durability are required. Most particularly, when using red phosphorescene materials, the visibility decreases as the color purity increases (i.e., the X value of the CIE chromacity coordinates becomes larger), thereby causing difficulty in providing high light emitting efficiency. Accordingly, red phosphorescence material that can provide characteristics of excellent chromacity coordinates (CIE color purity of X=0.65 or more), enhanced light emitting efficiency, and extended durability needs to be developed.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to red phosphorescence compounds and an organic electro-luminescence device using the same that substantially obviate one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide an organic electroluminescence device having high color purity, high brightness, and long durability by combining the compound shown in Formula 1, which is used as a dopant in a light emitting layer of the organic EL device.
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 red phosphorescence compound is indicated as Formula 1 below:
Herein each of R1, R2, R3, and R4 may be one of substituted or non-substituted C1 to C6 alkyl groups with disregard of one another. And, each of the C1 to c6 alkyl groups may be selected from a group consisting of methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and t-butyl.
Additionally,
may include 2,4-pentanedione
2,2,6,6,-tetra-methylheptane-3,5-dione
1,3-propanedione
1,3-butanedione
3,5-heptanedione
1,1,1-trifluoro-2,4-pentanedione
1,1,1,5,5,5-hexafluoro-2,4-pentanedione
and 2,2-dimethyl-3,5-hexanedione
Moveover,
may be any one of the following chemical formulas:
Furthermore, the Formula 1 may be any one of the following chemical formulas:
In another aspect of the present invention, in an organic electroluminescence device including an anode, a hole injecting layer, a hole transport layer, a light emitting layer, an electron transport layer, an electron injecting layer, and a cathode serially deposited on one another, the organic electroluminescence device may use any one of the above-described formulas as a dopant of the light emitting layer.
Herein, any one of Al and Zn metallic complexes and a carbazole derivative may be used as a host of the light emitting layer, and usage of the dopant may be within the range of 0.1 wt. % to 50 wt. %. The efficiency of the present invention may be provided when the amount of dopant used is within the above-described range. Furthermore, a ligand of each of the Al and Zn metallic complexes may include quinolyl, biphenyl, isoquinolyl, phenyl, methylquinolyl, dimethyl-quinolyl, dimethyl-isoquinolyl, and wherein the carbazole derivative may include CBP.
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 embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 illustrates a graph showing a decrease in visibility as color purity of an organic EL device increases (i.e., as the X value of chromacity coordinates becomes greater); and
FIG. 2 illustrates structural formula of NPB, copper (II) phthalocyanine (CuPc), (bpt) 2 Ir(acac), Alq 3 , BAlq, and CBP, which are compounds used in embodiments of 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.
A method of combining the red phosphorescence compound according to the present invention will now be described. An iridium (lll)(2-(3-methylphenyl)-7-methyl-quinolinato-N,C 2 )(2,4-pentanedionate-0,0) compound, which is shown as A-2 among the red phosphorescene compounds used in the organic EL device according to the present invention.
COMBINATION EXAMPLE
1. Combination of 2-(3-methylphenyl)-7-methyl-quinoline
3-methyl-phenyl-boric acid (1.3 mmol), 2-chloro-7-methyl-quinoline (1 mmol), tetrakis (triphenyl phosphine) palladium(0) (0.05 mmol), and potassium carbonate (3 mmol) are dissolved in a two-neck round bottom flask containing THF (30 ml) and H 2 O (10 ml). The mixture is then stirred for 24 hours in a bath of 100 degrees Celsius (° C.). Subsequently, when reaction no longer occurs, the THF and toluene are discarded. The mixture is extracted by using dichloromethane and water, which is then treated with vacuum distillation. Then, after filtering the mixture with a silica gel column, a solvent is treated with vacuum distillation. Thereafter, by using dichloromethane and petroleum ether, the mixture is re-crystallized and filtered, thereby yielding solid 2-(3-methylphenyl)-7-methyl-quinoline.
2. Formation of Chloro-cross-linked Dimer Complex
Iridium chloride (1 mmol) and 2-(3-methylphenyl)-7-methyl-quinoline (2.5 mmol) are mixed in a 3:1 liquid mixture (30 ml) of 2-ethoxyethanol and distilled water. Then, the mixture is refluxed for 24 hours. Thereafter, water is added so as to filter the solid form that is produced. Subsequently, the solid form is washed by using methanol and petroleum ether, thereby yielding the chloro-cross-linked dimer complex.
3. Formation of Iridium (lll)(2-(3-methylphenyl)-7-methyl-quinolinato-N,C 2 )(2,4-pentanedionate-0,0)
A chloro-cross-linked dimer complex (1 mmol), 2,4-pentane dione (3 mmol), and Na 2 CO 3 (6 mmol) are mixed into 2-ethoxyethanol (30 ml) and refluxed for 24 hours. The refluxed mixture is then cooled at room temperature. Thereafter, distilled water is added to the cooled mixture, which is filtered so as to yield a solid form. Subsequently, the solid form is dissolved in dichloromethane, which is then filtered by using silica gel. Afterwards, the dichloromethane is treated with vacuum suction, and the solid form is washed by using methanol and petroleum ether, so as to obtain the chemical compound.
Hereinafter, examples of preferred embodiments will be given to describe the present invention. It will be apparent that the present invention is not limited only to the proposed embodiments.
EMBODIMENTS
1. First Embodiment
An ITO glass substrate is patterned to have a light emitting area of 3 mm×3 mm. Then, the patterned ITO glass substrate is washed. Subsequently, the substrate is mounted on a vacuum chamber. The standard pressure is set to 1×10 −6 torr. Thereafter, layers of organic matter are formed on the ITO substrate in the order of CuPC (200 Å), NPB (400 Å), CBP+(btp) 2 Ir(acac)(7%) (200 Å), a hole blocking layer (100 Å), Alq 3 (300 Å), LiF (5 Å), and Al (1000 Å).
When forming a hole blocking layer using BAlq, the brightness is equal to 689 cd/m 2 (8.1 V) at 0.9 mA. At this point, CIE x=0.651, y=0.329. Furthermore, the durability (half of the initial brightness) lasts for 1600 hours at 2000 cd/m 2 .
2. Second Embodiment
An ITO glass substrate is patterned to have a light emitting area of 3 mm×3 mm. Then, the patterned ITO glass substrate is washed. Subsequently, the substrate is mounted on a vacuum chamber. The standard pressure is set to 1×10 −6 torr. Thereafter, layers of organic matter are formed on the ITO substrate in the order of CuPC (200 Å), NPB (400 Å), BAlq+A-2(7%) (200 Å), Alq 3 (300 Å), LiF (5 Å), and Al (1000 Å).
At 0.9 mA, the brightness is equal to 1448 cd/m 2 (6.2 V). At this point, CIE x=0.644, y=0.353. Furthermore, the durability (half of the initial brightness) lasts for 8000 hours at 2000 cd/m 2 .
3. Third Embodiment
An ITO glass substrate is patterned to have a light emitting area of 3 mm×3 mm. Then, the patterned ITO glass substrate is washed. Subsequently, the substrate is mounted on a vacuum chamber. The standard pressure is set to 1×10 −6 torr. Thereafter, layers of organic matter are formed on the ITO substrate in the order of CuPC (200 Å), NPB (400 Å), BAlq+A-5(7%) (200 Å), Alq 3 (300 Å), LiF (5 Å), and Al (1000 Å).
At 0.9 mA, the brightness is equal to 1378 cd/m 2 (6.0 V). At this point, CIE x=0.659, y=0.351. Furthermore, the durability (half of the initial brightness) lasts for 7000 hours at 2000 cd/m 2 .
COMPARISON EXAMPLE
An ITO glass substrate is patterned to have a light emitting area of 3 mm×3 mm. Then, the patterned ITO glass substrate is washed. Subsequently, the substrate is mounted on a vacuum chamber. The standard pressure is set to 1×10 −6 torr. Thereafter, layers of organic matter are formed on the ITO substrate in the order of CuPC (200 Å), NPB (400 Å), BAlq+(btp) 2 Ir(acac) (7%) (200 Å), Alq 3 (300 Å), LiF (5 Å), and Al (1000 Å).
At 0.9 mA, the brightness is equal to 780 cd/m 2 (7.5 V). At this point, CIE x=0.659, y=0.329. Furthermore, the durability (half of the initial brightness) lasts for 2500 hours at 2000 cd/m 2 .
In accordance with the above-described embodiments and comparison example, the characteristics of efficiency, chromacity coordinates, brightness, and durability are shown in Table 1 below.
TABLE 1
Durability(h)
Current
Power
½ of
Voltage
Current
Brightness
Efficiency
Efficiency
CIE
CIE
initial
Device
(V)
(mA)
(cd/m 2 )
(cd/A)
(1 m/W)
(X)
(Y)
brightness
First
8.1
0.9
690
6.9
2.7
0.651
0.329
1600
Embodiment
Second
6.2
0.9
1450
14.5
7.3
0.644
0.353
8000
Embodiment
Third
6.0
0.9
1378
13.8
7.2
0.659
0.351
7000
Embodiment
Comparison
7.5
0.9
780
7.8
3.3
0.659
0.329
2500
Example
As shown in Table 1, the device is operated with high efficiency at a low voltage even when the color purity is high. Furthermore, the current efficiency of the second embodiment has increased by 100% or more as compared to the comparison example. Additionally, the durability of the second embodiment has increased to three times that of the comparison example.
Table 2 below shows the characteristics of efficiency, chromacity coordinates, and brightness in accordance with the increase in voltage and electric current in the organic electroluminescence device according to the second embodiment of the present invention.
TABLE 2 Current Power Voltage Current Brightness Efficiency Efficiency CIE CIE (V) (A(mA/cm 2 ) (cd/m 2 ) (cd/A) (1 m/W) (X) (Y) 5.0 1.111 168.6 15.2 9.5 0.645 0.353 5.5 3.333 500.8 15.0 8.5 0.645 0.353 6.0 7.777 1139 14.6 7.6 0.644 0.354 6.5 16.666 2309 13.9 6.6 0.643 0.354 7.0 33.333 4275 12.9 5.7 0.643 0.355 7.5 66.666 7664 11.5 4.8 0.641 0.356
As shown in Table 2, the second embodiment provides excellent efficiency, and the chromacity coordinates according to the driving voltage also maintains high color purity.
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. | Red phosphorescene compounds and organic electro-luminescence device using the same are disclosed. In an organic electroluminescence device including an anode, a hole injecting layer, a hole transport layer, a light emitting layer, an electron transport layer, an electron injecting layer, and a cathode serially deposited on one another, the organic electroluminescence device may use a compound as a dopant of the light emitting layer. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 333,672 filed Dec. 23, 1981. Now U.S. Pat. No. 4,435,401, issued Mar. 6, 1984.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to therapeutic agents which are novel derivatives of 4-amino-6,7-dimethoxy-2-piperazinoquinazoline, their use as regulators of the cardiovascular system, particularly in the treatment of hypertension and pharmaceutical compositions containing them.
2. Description of the Prior Art
U.S. Pat. No. 3,511,836 discloses 4-amino-6,7-dimethoxyquinazolines and U.S. Pat. No. 3,669,968 discloses related 6,7,8-trimethoxyquinazolines of the formula ##STR2## useful as antihypertensive agents, wherein R a is hydrogen or methoxy, respectively, and R b is inter alia, phenyl, benzyl, benzoyl, furoyl, thenoyl and pyridinecarbonyl. One of these compounds, 2-[4-(2-furoyl)piperazin-1-yl]-4-amino-6,7-dimethoxyquinazoline, is a clinically useful antihypertensive agent marketed under the generic name "prazosin".
U.S. Pat. No. 3,517,005 discloses antihypertensives including those of the formula ##STR3## where R c is hydrogen or alkyl and R d is inter alia an aryl hydrocarbon moiety.
European Patent Application No. 22481 published Jan. 21, 1981 discloses antihypertensive agents of the formula ##STR4## where n is 3, 4 or 5 and R e is, inter alia, a nitrogen-containing heterocyclic group, e.g., pyridyl, pyrimidinyl, quinolyl or quinazolyl; and Y is e.g. a substituted or unsubstituted amino group.
SUMMARY OF THE INVENTION
The present invention discloses new 4-amino-6,7-dimethoxyquinazolines of the formula ##STR5## or a pharmaceutically acceptable acid addition salt thereof, wherein R is a nitrogen heterocyclic group linked to the piperazine ring by one of its carbon atoms, said heterocyclic group being a member selected from the group consisting of ##STR6## where R 1 is hydrogen and R 2 is 6,7-dimethoxy-1,2,3,4-tetrahydroisoquinolin-2-yl, or R 1 and R 2 are each a member selected from the group consisting of hydrogen, hydroxy, F, Cl, Br, I, (alk)R 3 , O(alk) R 3 , S(alk) R 3 , NR 4 R 5 , C 6 H 4 R 6 and OC 6 H 4 R 6 and (alk) is (C 1 -C 4 ) alkylene, R 3 is hydrogen or C 6 H 4 R 6 , when taken separately, R 4 is hydrogen or (C 1 -C 4 ) alkyl and R 5 is hydrogen, phenyl, (alk)R 3 or (C 3 -C 7 ) cycloalkyl, or taken together with the nitrogen atom to which they are attached, R 4 and R 5 form a 1-pyrrolidinyl, piperidino, 4-methylpiperazino, morpholino, or thiomorpholino group, and R 6 is hydrogen, F, Cl, Br, I, (C 1 -C 4 ) alkyl or (C 1 -C 4 ) alkoxy.
Hydroxy substituted heterocyclic groups, R, may occur in tautomeric form. Such tautomers are within the scope of the invention.
Particularly preferred values of substituent R are the optionally substituted 2-pyrimidinyl, 4-pyrimidinyl, 1,3,5-triazin-2-yl, 3-pyridazinyl and 2-pyrazinyl moieties below ##STR7##
More particularly preferred compounds of the invention are those where R has one of the above values and:
a. one of R 1 and R 2 is hydrogen and the other is a member selected from the group consisting of hydroxy, Cl, Br, phenyl, phenoxy, (alk)R 3 , O(alk)R 3 , S(alk)R 3 , NR 4 R 5 and 6,7-dimethoxy-1,2,3,4-tetrahydroisoquinolin-2-yl, where R 3 is hydrogen, R 4 is hydrogen or (C 1 -C 4 ) alkyl and R 5 is hydrogen, phenyl, (C 5 -C 6 ) cycloalkyl or (alk)R 3 where R 3 is hydrogen, or R 4 and R 5 taken together with the nitrogen atom to which they are attached form a morpholino group; or
b. R 1 and R 2 are the same and are each hydrogen, phenoxy, O(alk)R 3 or NHR 5 where R 5 is hydrogen or (alk)R 3 , and R 3 is hydrogen.
Even more particularly preferred are those compounds of formula (I) wherein R has one of the values below. ##STR8##
Pharmaceutically acceptable acid addition salts of the compounds of the invention are those formed from acids which form non-toxic acid addition salts containing pharmaceutically acceptable anions, such as the hydrochloride, hydrobromide, sulphate or bisulphate, phosphate or acid phosphate, acetate, maleate, fumarate, succinate, lactate, tartrate, citrate, glucconate, saccharate, mesylate and p-toluenesulphonate salts.
The compounds of formula (I) are valuable antihypertensive agents having significant advantages over the prior art.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the formula (I) can be prepared by reacting a quinazoline of the formula: ##STR9## where Q is a facile leaving group, e.g., Cl, Br, C 1 -C 4 alkoxy or C 1 -C 4 alkylthio; with a piperazine of the formula: ##STR10## where R is as previously defined. A particularly preferred value for Q is Cl.
In a typical procedure the reactants are heated together, e.g., at 70°-150° C., preferably under reflux, in a suitable solvent, e.g., r-butanol, for up to about 25 hours, the exact period of time of course depending on the nature of the reactants and the temperature employed, as will be known to those skilled in the art. The product can then be isolated and purified by conventional procedures.
If compound (III) is added in the form of an acid addition salt, then a tertiary amine base such as triethylamine is preferably added to the reaction mixture to release the free base of formula (III).
The starting materials of formula (III) are either known compounds or may be prepared by methods analogous to those of the prior art, many of such methods being illustrated in Preparations A to I. The starting quinazoline compounds of formula (II) are well known in the art; see e.g., U.S. Pat. No. 3,511,836.
The compounds of the formula (I) can also be prepared by reacting a 2-piperazinoquinazoline of the formula: ##STR11## with a heterocycle of the formula:
R--Q (V)
where
R and Q are as previously defined and
Q is preferably Cl.
The reaction may be carried out in a similar manner to the previous method. Similarly, the product may be isolated and purified by conventional procedure. The starting materials of the formula (V) are either known compounds of may be prepared by methods analogous to those of the prior art. The starting 2-piperazinoquinazoline (IV) is provided, for example, in U.S. Pat. No. 3,511,836.
Some of the compounds of the formula (I) can be prepared from other compounds of the formula (I). For example, compounds of the formula (I) in which R contains NR 4 R 5 , where R 4 and R 5 are as defined for formula (I), can be prepared by reacting the corresponding compound in which R is a halogen substituted moiety with the appropriate amine of the formula R 4 R 5 NH. Generally, fairly vigorous reaction conditions are necessary, e.g., heating the reactants in a suitable solvent, e.g., n-butanol, at up to 180° C. in a bomb, for up to about 48 hours. A preferred halogen substituent is chloro.
Requisite starting compounds R Q, as defined above, are either known compounds or are prepared by analogous methods well known to those of skill in the art, see for example, "Comprehensive Organic Chemistry", by Barton and Ollis, Pergamon Press, New York, N.Y., Vol. 4, 1979, pp. 85-103 and 145-153 and references cited therein.
The pharmaceutically acceptable acid addition salts of the compounds of the formula (I) can be prepared by conventional procedures, e.g., by reacting the free base with the appropriate acid in an inert organic solvent, and collecting the resulting precipitate of the salt by filtration. If necessary, the product may then be recrystallized to purify it.
The antihypertensive activity of the compounds of the formula (I) is shown by their ability to lower the blood pressure of conscious spontaneously hypertensive rats and conscious renally hypertensive dogs, when administered orally at doses of up to 5 mg/kg.
The compounds of the invention can be administered alone, but will generally be administered in admixture with a pharmaceutical carrier selected with regard to the intended route of administration and standard pharmaceutical practice. For example, they may be administered orally in the form of tablets containing such excipients as starch or lactose, or in capsules either alone or in admixture with excipients, or in the form of elixirs or suspensions containing flavoring or coloring agents. They may be injected parenterally, for example, intramuscularly, intravenously or subcutaneously. For parenteral administration, they are best used in the form of a sterile aqueous solution which may contain other solutes, for example, enough salts or glucose to make the solution isotonic.
Thus the invention also provides a pharmaceutical composition comprising an antihypertensive effective amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salt thereof together with a pharmaceutically acceptable diluent or carrier.
The invention further provides a compound of the formula (I) or a pharmaceutically acceptable acid addition salt thereof, for use in treating hypertension in mammals, including humans.
The compounds of the invention can be administered to mammals, including humans, for the treatment of hypertension by either the oral or parenteral routes, and may be administered orally at dosage levels approximately within the range 1 to 20 mg/day for an average adult patient (70 kg) given in a single dose or up to 3 divided doses. Intravenous dosage levels would be expected to be about 1/5 to 1/10th of the daily oral dose. Thus for an average adult patient, individual oral doses in tablet or capsule form will be approximately in the range from 1/3 to 20 mg of the active compound. Variations will necessarilly occur depending on the weight and condition of the subject being treated and the particular route of administration chosen as will be known to those skilled in the art.
The invention yet further provides a method of treating a mammal, including a human being, having hypertension, which comprises administering to the mammal an antihypertensive amount of a compound of the formula (I) or pharmaceutically acceptable acid addition salt thereof or pharmaceutical composition as defined above.
The invention is illustrated by the following Examples, in which all temperatures are in °C.
EXAMPLE 1
4-Amino-6,7-dimethoxy-2-[4-(4-phenylpyrimidin-2-yl)piperazino] quinazoline, hemihydrate ##STR12##
4-Amino-6,7-dimethoxy-2-piperazino-quinazoline (3.44 g, 0.012 mole) and 2-chloro-4-phenylpyrimidine (2.5 g, 0.011 mole) [J. Chem. Soc., 2328 (1951)] in n-butanol (250 ml) were heated under reflux for six hours. After cooling the solid product was collected, washed with diethylether, and partitioned between chloroform and saturated aqueous sodium carbonate solution. The chloroform layer was separated, the aqueous layer extracted with chloroform and the combined chloroform layers were washed with water, dried (Na 2 SO 4 ) and evaporated in vacuo. The residue (5 g) was chromatographed on silica eluting with chloroform and chloroform-methanol (97.5:2.5 by volume). Appropriate fractions were combined, evaporated and the resulting solid crystallized from dimethylformamide (DMF)/diethyl ether to give 4-amino-6,7-dimethoxy-2-[4-(4-phenylpyrimidin-2-yl)-piperazino] quinazoline hemihydrate, (2.28 g), m.p. 250° C. (dec).
Analysis %: Found: C, 63.5; H, 5.8; N, 21.8. Calculated for C 24 H 25 N 7 O 2 .1/2H 2 O: C, 63.7; H, 5.8; N, 21.7.
The following Examples were carried out in the same general manner as Example 1, but in some cases the reaction mixture was evaporated in vacuo and then purified as described. Other modifications were as follows. In Example 4 the product from chromatography was converted to the dihydrochloride in the standard manner, using hydrogen chloride in a suitable solvent. In Example 5, the product was collected from the cooled reaction mixture then recrystallized from ethanol. In Examples 7, 8, 14 and 18, the initial reaction was carried out in ethanol and in Examples 8 and 14 the products, after chromatography, were converted to the dihyrochloride salts. In Example 10, the product from chromatography was further purified by preparative high pressure liquid chromatography (HPLC). In Examples 11 and 12, after basification and extraction, the residue was recrystallized from methanol. In Example 13, the solid product from the reaction mixture was taken up in DMF/diethyl ether and precipitated with water. In Example 15, the product from chromatography was converted to the citrate salt using citric acid in a suitable solvent, recrystallized from methanol, basified, then treated with maleic acid, and the maleate salt recrystallized from methanol.
__________________________________________________________________________ ##STR13## Analysis %Example Form Isolated (calculated figures in brackets)No. R and m.p. °C. C H N__________________________________________________________________________ ##STR14## Free base 202-203° 57.1 (57.4 6.0 5.8 25.1 24.7) 3 ##STR15## hemihydrate 191-192° 61.6 (61.5 5.6 5.6 20.5 20.9) 4 ##STR16## dihydrochloride 21/2 H.sub.2 O 245-248° 43.5 (43.2 5.1 5.8 22.3 22.4) 5 ##STR17## hydrochloride 1/4 H.sub.2 O 262-264° 52.2 (52.2 6.2 6.2 24.4 24.3) 6 ##STR18## 1/3 ethanolate 225-226° 59.2 (59.5 6.2 6.4 24.9 24.7) 7 ##STR19## free base 227° 58.5 (58.4 6.4 6.1 23.4 23.8) 8 ##STR20## dihydrochloride hydrate 265-269° 48.9 (48.8 5.6 6.1 19.0 19.0) 9 ##STR21## free base 194-195° 56.0 (56.2 5.9 5.9 23.2 22.9) 10 ##STR22## free base 145-150° 61.9 (62.0 5.1 5.2 19.9 20.0) 11 ##STR23## free base 130-133° 55.1 (55.5 6.7 6.7 30.8 30.8) 12 ##STR24## free base hydrate 276-177° 48.9 (49.0 5.6 5.8 33.4 33.6) 13 ##STR25## hydrochloride hydrate 225-226° 46.9 (47.3 5.7 5.6 23.1 23.3) 14 ##STR26## dihydrochloride 267-268° 54.3 (54.1 5.3 5.1 18.4 18.4) 15 ##STR27## dimaleate hydrate 224-226° 55.3 5.2 5.5 13.7 13.9) 16 ##STR28## free base 1/2 mole EtOAc hemihydrate 187-188.deg ree. 57.2 (57.0 6.7 6.7 24.2 24.2) 17 ##STR29## free base 263-265° 59.3 (59.3 6.6 6.4 23.3 23.1) 18 ##STR30## free base hemihydrate 239-241° 58.5 (58.1 6.4 6.5 22.8 22.6) 19 ##STR31## free base 238-239° 54.9 (55.2 5.5 5.6 23.4 23.7)__________________________________________________________________________
EXAMPLE 20
4-Amino-6,7-dimethoxy-2-[4-(2-phenoxypyrimidin-4-yl)piperazino] quinazoline 3/4 hydrate ##STR32##
4-Amino-2-chloro-6,7-dimethoxyquinazoline (0.8 g, 3.3 mmole) and 2-phenoxy-4-piperazinopyrimidine dihydrochloride (1.2 g, 3.6 mmole) were heated under reflux in n-butanol (50 ml) overnight. The mixture was then evaporated in vacuo and the residue partitioned between chloroform/methanol/saturated aqueous sodium carbonate solution (300 ml:100 ml:50 ml). The chloroform/methanol layer was separated, dried (Na 2 SO 4 ), evaporated in vacuo then the residue (1 g) chromatographed on silica gel (85 g). The column was eluted with chloroform, then chloroform containing 2.5% methanol by volume, appropriate fractions combined, evaporated in vacuo and the residue recrystallized from ethanol to give the title compound, (0.14 g) m.p. 253°-254° C.
Analysis %: Found: C, 60.8; H, 5.5; N, 20.7. Calculated for C 24 H 25 N 7 O 3 .3/4H 2 O: C, 60.9; H, 5.7; N, 20.7.
The following compounds were prepared by the procedure of Example 20, except that in some cases triethylamine was included in the reaction mixture and other modifications were as follows:
In Example 21, the reaction mixture was evaporated, the residue partitioned between chloroform/water, the solid collected, boiled with methanol, filtered and the filtrate evaporated. The residue was then purified by chromatography. In Example 22 the reaction mixture was evaporated in vacuo and the residue crystallized from methanol/diethyl ether; in Example 24 cooling of the reaction mixture yielded 4-amino-2-dimethylamino-6,7-dimethoxyquinazoline formed due to inadvertent presence of dimethylamine in the piperazino starting material. The mother liquors were treated as in the general example, then the product from chromatography purified by preparative high pressure liquid chromatography and converted to the maleate salt in the standard manner using maleic acid in a suitable solvent. In Example 27, the solid product was collected from the cooled reaction mixture and was recrystallized from dimethylformamide/diethyl ether. In Example 28, the solid product was collected, recrystallized from methanol then converted to the hydrochloride salt in the standard manner using hydrogen chloride in a suitable solvent. In Example 29 the solid product was collected and recrystallized from dimethylformamide. In Example 30 the product from chromatography was converted to the maleate salt using maleic acid which salt was crystallized from methanol. In Example 31 the solid product was collected then washed with diethyl ether.
__________________________________________________________________________ ##STR33## Analysis %Example Form Isolated (Theoretical in brackets)No. R and m.p., °C. C H N__________________________________________________________________________21 ##STR34## dihydrochloride 265-266° 49.0 (49.1 5.3 5.3 22.5 22.3) 22 ##STR35## dihydrochloride dihydrate 255-265° 46.2 (46.2 5.8 6.2 21.8 21.6) 23 ##STR36## free base 1/4 hydrate 265° 54.5 (54.5 5.4 5.7 24.9 24.7) 24 ##STR37## dimaleate hemihydrate 203-204° 51.5 (51.6 5.4 5.4 17.4 17.2) 25 ##STR38## free base 270-272° 62.8 (62.7 5.6 5.5 21.2 21.3) 26 ##STR39## free base 247-248° 59.1 (59.3 6.6 6.4 22.7 23.1) 27 ##STR40## free base 285-287° 57.3 (57.4 6.0 5.8 24.9 24.7) 28 ##STR41## dihydrochloride 13/4 hydrate 266-268° 52.4 (52.6 5.5 5.6 18.3 17.9) 29 ##STR42## hydrochloride sesquihydrate 214-215° 50.6 (50.2 5.4 5.9 22.4 22.8) 30 ##STR43## maleate hydrate 247-248° 50.6 (50.8 5.5 5.8 19.0 19.0) 31 ##STR44## hydrochloride 291-293° 53.2 (58.5 5.6 5.5 24.5 24.3)__________________________________________________________________________
EXAMPLE 32
4-Amino-6,7-dimethoxy-2-[4-(6-hydroxypyridazin-3-yl)piperazino] quinazoline
Triethylamine (2.5 g, 0.025 mole) and 4-(6-hydroxypyridazin-3-yl)piperazine hydrobromide (2.7 g, 0.011 mole) in n-butanol (150 ml) were heated to reflux, then filtered and 4-amino-2-chloro-6,7-dimethoxyquinazoline (2.4 g, 0.010 mole) added to the filtrate. The mixture was heated under reflux for three hours then left at room temperature for 66 hours. The solid product was collected, washed with diethyl ether, then slurried in hot methanol (50 ml), filtered and washed again with hot methanol followed by hot isopropanol. A slurry of the product in aqueous methanol (methanol:water 1:3 by volume) was basified to pH 12 with dilute ammonium hydroxide and extracted with chloroform (100 ml) followed by chloroform-methanol (95:5; 3×100 ml). The combined organic layers were dried (Na 2 SO 4 ) and evaporated in vacuo to give a solid (0.6 g). The aqueous fraction was filtered and the solid washed with water and dried to give a further 1.6 g of solid product identical when analyzed by thin layer chromatography to the first solid. The two solids were combined then recrystallized from dimethylformamide/diethyl ether and the resulting solid washed with diethyl ether, hot isopropanol and diethyl ether again to give 4-amino-6,7-dimethoxy-2-[4-(6-hydroxypyridazin-3-yl)piperazino] quinazoline (1.3 g), m.p. 296°-297° C.
Analysis %: Found: C, 55.9; H, 5.7; N, 25.2. Calculated for C 18 H 21 N 7 O 3 : C, 56.4; H, 5.5; N, 25.6.
EXAMPLE 33
4-Amino-6,7-dimethoxy-2-[4-(6-chloropyridazin-3-yl)piperazino] quinazoline
4-Amino-6,7-dimethoxy-2-piperazinoquinazoline (3.0 g, 10.4 mmole), 3-chloro-6-methoxy-pyridazine (3.96 g, 27.4 mmole) and triethylamine (5.0 g, 49.5 mmole) in n-pentanol (210 ml) were heated under reflux for 25 hours. The solvent was evaporated in vacuo and the residue partitioned between chloroform and saturated aqueous sodium carbonate solution. The organic layer was separated, washed with water, dried (Na 2 SO 4 ) and evaporated in vacuo. The residue was chromatographed on silica gel (200 g) eluting with chloroform followed by 5% methanol in chloroform. Further purification of the major product by HPLC using a Waters 500 Prep. LC/system, eluting with 6% by volume methanol in methylene chloride at a flow rate of 0.15 liters per minute gave the desired product which was recrystallized from methanol, m.p. 269°-270° C. (0.5 g).
Analysis %: Found: C, 53.7; H, 4.9; N, 24.2. Calculated for C 18 H 20 ClN 7 O 2 : C, 53.8; H, 5.0; N, 24.4.
EXAMPLE 34
4-Amino-6,7-dimethoxy-2-[4-(2-chloropyrimidin-4-yl)piperazino] quinazoline
4-Amino-6,7-dimethoxy-2-piperazino-quinazoline (30.0 g, 0.104 mole), 2,4-dichloropyrimidine (17.3 g, 0.117 mole) and triethylamine (20.5 g, 0.203 mole) in ethanol (1200 ml) were heated at reflux for three hours. The solid which separated on cooling was filtered, slurried in hot isopropanol (500 ml), filtered and washed with hot methanol. The product was partitioned between 5% by volume methanol in methylene chloride and 10% (w/w) aqueous sodium carbonate solution, the organic layer separated, washed with water, dried (Na 2 SO 4 ) and evaporated in vacuo. The resulting solid was slurried in hot isopropanol, filtered and washed with hot isopropanol to afford 20 g. of the title compound, m.p. 266° C.
Analysis %: Found: C, 53.75; H, 5.0; N, 24.7. Calculated for C 18 H 20 ClN 7 O 2 : C, 53.8; H, 5.0; N, 24.4.
EXAMPLE 35
Employing the above methods with the appropriate starting materials in each case, the following compounds are obtained in like manner.
______________________________________ ##STR45## R______________________________________1,3,5-triazin-2-yl4-(p-Fluorophenyl)pyrimidin-2-yl4-(m-Iodophenyl)pyrimidin-2-yl2-(o-Methylphenyl)pyrimidin-4-yl2-(p-Isopropylphenyl)pyrimidin-4-yl2-(m-t-Butylphenyl)pyrimidin-4-yl2-(p-t-Butoxyphenyl)pyrimidin-4-yl4-(m-Ethoxyphenyl)pyrimidin-2-yl4-(o-Methoxyphenyl)pyrimidin-2-yl4-Phenoxypyrimidin-2-yl4-(p-Chlorophenoxy)pyrimidin-2-yl4-(o-Bromophenoxy)pyrimidin-2-yl2-(m-Fluorophenoxy)pyrimidin-4-yl2-(p-Methylphenyl)pyrimidin-4-yl2-(p-Ethylphenyl)pyrimidin-4-yl4-(o-Isopropylphenyl)pyrimidin-2-yl4-(o-Methoxyphenyl)pyrimidin-2-yl4-n-Propylpyrimidin-2-yl6-sec-Butylpyrimidin-4-yl6-Benzylpyrimidin-4-yl4-(2-Phenylethyl)-pyrimidin-2-yl4-[2-(p-Fluorophenyl)ethyl]pyrimidin-2-yl4-[3-(m-Chlorophenyl)propyl]pyrimidin-2-yl2-[2-(p-Methylphenyl)propyl]pyrimidin-4-yl2-[3-(o-Ethoxyphenyl)propyl]pyrimidin-4-yl4-[3-(p-t-Butoxyphenyl)propyl]pyrimidin-2-yl4-[3-(m-n-Butylphenyl)propyl]pyrimidin-2-yl4-[4-(p-Bromophenyl)butyl]pyrimidin-2-yl4-[3-(p-Iodophenyl)butyl]pyrimidin-2-yl2-[4-(phenylbutyl)pyrimidin-4-yl4-Benzyloxypyrimidin-2-yl4-(p-Chlorophenyl)methylpyrimidin-2-yl2-Ethoxypyrimidin-4-yl4-Isopropoxypyrimidin-2-yl4-n-Butoxypyrimidin-2-yl4-[2-(m-Bromophenyl)ethoxy]pyrimidin-2-yl2-[1-(p-Methoxyphenyl)ethoxypyrimidin-4-yl2-[3-(o-Ethylphenyl)propoxypyrimidin-4-yl2-[4-(p-Fluorophenyl)butoxypyrimidin-4-yl4-Methylthiopyrimidin-2-yl4-Isopropylthiopyrimidin-2-yl2-n-Butylthiopyrimidin-4-yl2-Benzylthiopyrimidin-4-yl6-(2-Phenylethylthio)pyrimidin-4-yl4-[4-(p-Chlorophenyl)butylthio] pyrimidin-2-yl4-[3-(m-Methoxyphenyl)propylthio]pyrimidin-2-yl4-Aminopyrimidin-2-yl4-Methylaminopyrimidin-2-yl4-n-Propylaminopyrimidin-2-yl6-n-Butylaminopyrimidin-4-yl6-Phenylaminopyrimidin-4-yl2-Benzylaminopyrimidin-4-yl4-(2-Phenylethyl)aminopyrimidin-2-yl4-(3-p-Chlorophenylpropyl)aminopyrimidin-2-yl4-N--Methyl-N--ethylaminopyrimidin-2-yl6-N--Phenyl-N--propylaminopyrimidin-4-yl6-N--Ethyl-N--sec-butylaminopyrimidin-4-yl4-N--Methyl-N--[4-(p-chlorophenyl)butyl]pyrimidin-2-yl4-Cycloheptylaminopyrimidin-2-yl4-Cyclohexylaminopyrimidin-2-yl2-N--Cyclopropyl-N--methylpyrimidin-4-yl2-N--Cyclobutyl-N--ethylpyrimidin-4-yl6-N--Cyclopentyl-N--isopropylpyrimidin-4-yl4-Morpholinopyrimidin-2-yl2-Thiomorpholinopyrimidin-4-yl2-[1-pyrrolidinyl]pyrimidin-4-yl6-Piperidinopyrimidin-4-yl6-(4-Methylpiperazino)pyrimidin-4-yl6-Benzylpyridazin-3-yl6-Fluoropyridazin-3-yl6-Bromopyridazin-3-yl6-(p-Bromophenyl)pyridazin-3-yl6-(o-Methylphenyl)pyridazin-3-yl6-(p-t-Butoxyphenyl)pyridazin-3-yl6-(m-Methoxyphenyl)pyridazin-3-yl6-(p-Chlorophenoxy)pyridazin-3-yl6-(p-Ethylphenoxy)pyridazin-3-yl6-(p-Ethoxyphenoxy)pyridazin-3-yl6-Methylpyridazin-3-yl6-Ethylpyridazin-3-yl6-Aminopyridazin-3-yl6-Methylaminopyridazin-3-yl5,6-Dimethylpyridazin-3-yl5-Amino-6-methoxypyridazin-3-yl5-Amino-6-ethoxypyridazin-3-yl5-Chloro-6-methoxypyridazin-3-yl6-Methylaminopyridazin-4-yl6-Chloro-5-ethylpyridazin-3-yl6-Chloro-5-methylpyridazin-3-yl6-Amino-5-methylpyridazin-3-yl4,6-Dimorpholino-1,3,5-triazin-2-yl6-Ethoxy-5-methylpyrazin-2-yl6-Ethoxypyrazin-2-yl5-Ethyl-6-methoxypyrazin-2-yl5,6-Dimethylpyrazin-2-yl6-Methylpyrazin-2-yl6-n-Butylpyrazin-2-yl6-isopropylpyrazin-2-yl5-Ethoxypyrazin-2-yl5-Methoxypyrazin-2-yl5-Dimethylamino-6-methylpyrazin-2-yl5-Morpholino-6-ethylpyrazin-2-yl5-n-Butyl-6-Methylaminopyrazin-2-yl5,6-Diethylpyrazin-2-yl5-Amino-6-methylpyrazin-2-yl5-Aminopyrazin-2-yl______________________________________
EXAMPLE 36
4-Amino-6,7-dimethoxy-2-[4-(2-morpholinopyrimidin-4-yl)-piperazino] quinazoline
4-Amino-6,7-dimethoxy-2-[4-(2-chloropyrimidin-4-yl)-piperazino] quinazoline (2.0 g, 5.0 mmole) and morpholine (1.1 g, 12.6 mmole) in n-butanol (150 ml) were heated in a bomb at 160° C. for 19 hours. The solvent was evaporated in vacuo and the residue partitioned between 5% methanol in chloroform and 5N sodium hydroxide solution. The organic layer was separated, washed with water, dried (Na 2 SO 4 ) and evaporated in vacuo. The residue was chromatographed on silica gel (20 g, "Kieselgel" (Trade Mark) 60H) eluting with chloroform. Appropriate fractions were combined and evaporated in vacuo. Crystallization from ethyl acetate gave 0.8 g of the desired product, m.p. 232°-233° C.
Analysis %: Found: C, 58.0; H, 6.3; N, 24.9. Calculated for C 22 H 28 N 8 O 3 : C, 58.4; H, 6.2; N, 24.8.
EXAMPLE 37
4-Amino-6,7-dimethoxy-2-[4-(2-{N-cyclopentyl-N-methylamino}pyrimidin-4-yl)piperazino] quinazoline was prepared in a manner similar to that of Example 36, starting from the product of Example 34 and N-cyclopentylmethylamine, but a temperature of 180° for 48 hours was required. The product was characterized as the dihydrochloride dihydrate, m.p. 333°-4° C.
Analysis %: Found: C, 50.0; H, 6.2; N, 19.8. Calculated for C 24 H 32 N 8 O 2 .2HCl.2H 2 O: C, 50.3; H, 6.7; N, 19.5.
EXAMPLE 38
4-Amino-6,7-dimethoxy-2-[4-(2-N-methylanilinopyrimidin-4-yl)piperazino] quinazoline, m.p. 252°-3° C., was prepared in a manner similar to Example 36, starting from the product of Example 34 and N-methylaniline.
Analysis %: Found: C, 63.4; H, 6.0; N, 23.8. Calculated for C 25 H 28 N 8 O 2 : C, 63.5; H, 6.0; N, 23.7.
EXAMPLE 39
In like manner the following products are prepared by the method of Examples 36-38 as outlined below ##STR46## where X is Cl or Br and R 4 and R 5 are as defined below.
______________________________________R.sup.4 R.sup.5______________________________________H CH.sub.3H C.sub.2 H.sub.5H CH(CH.sub.3).sub.2H (CH.sub.2).sub.3 CH.sub.3H CH.sub.2 CH(CH.sub.3).sub.2H C.sub.6 H.sub.5H cyclopropylH cyclopentylH cyclohexylH cycloheptylCH.sub.3 C.sub.2 H.sub.5C.sub.2 H.sub.5 C.sub.2 H.sub.5n-C.sub.3 H.sub.7 C.sub.2 H.sub.5n-C.sub.3 H.sub.7 n-C.sub.4 H.sub.9n-C.sub.4 H.sub.9 n-C.sub.4 H.sub.9CH.sub.3 cyclopropylC.sub.2 H.sub.5 cyclobutyln-C.sub.3 H.sub.7 cyclopentylCH.sub.3 cyclohexylH benzylH 2-phenylethylCH.sub.3 3-phenylpropylC.sub.2 H.sub.5 3-phenylbutyl______________________________________
or R 4 +R 5 +N is:
thiomorpholin,
piperidino
4-methylpiperazino
EXAMPLE 40
By employing a compound of formula (I) where R is 4-halo-1,3,5-triazin-2-yl or 4,6-dihalo-1,3,5-triazin-2-yl, the following compounds are obtained by the methods of Examples 36-38, where halo is Cl or Br. ##STR47## where R 1 is hydrogen or NR 4 R 5 and R 2 is NR 4 R 5 where R 4 and R 5 are as defined in Example 39.
EXAMPLE 41
To a solution of 2.0 mmole 4-amino-6,7-dimethoxy-2-[4-(2-chloropyrimidin-4-yl)-piperazino] quinazoline in n-butanol is added 20 ml of 0.1N hydrogen chloride in butanol. The resulting mixture is stirred for a few minutes, the solvent evaporated in vacuo to a small volume and the residue treated with ethyl ether to complete the precipitation of the hydrochloride salt.
In similar manner the remaining compounds of formula (I) are converted to hydrochloride salts.
When the hydrogen chloride employed above is replaced by one of the following acids the corresponding salts are obtained in like manner:
hydrogen bromide, hydrogen iodine, sulfuric acid, ammonium bisulfate, phosphoric acid, potassium dihydrogen phosphate, acetic acid, maleic acid, fumaric acid, succinic acid, lactic acid, tartaric acid, citric acid, gluconic acid, saccharic acid, methylsulfonic acid and p-toluenesulfonic acid.
PREPARATION A
2-Phenoxy-4-piperazinopyrimidine
i. 2-Chloro-4-(4-formylpiperazino)pyrimidine
1-Formylpiperazine (38.5 g) and triethylamine (34 g) in ethanol (500 ml) were added slowly to a stirred solution of 2,4-dichloropyrimidine (50 g) in ethanol (2.5 ml) at room temperature. The mixture was stirred at room temperature for 24 hours then evaporated in vacuo and the residue partitioned between chloroform and water. The organic phase was washed with water and the combined aqueous phases extracted with chloroform. The combined chloroform extracts were dried (Na 2 SO 4 ), evaporated in vacuo and the residue was crystallized twice from ethyl acetate to give 2-chloro-4-(4-formylpiperazino)pyrimidine, (24 g), m.p. 125°-126° C.
Analysis %: Found: C, 47.5; H, 4.8; N, 24.4. Calculated for C 9 H 11 ClN 4 O: C, 47.7; H, 4.9; N, 24.7.
A further 6.0 g of product was obtained on evaporation of the ethyl acetate to half volume and cooling.
ii. 2-Phenoxy-4-(4-formylpiperazino)pyrimidine 1/4 hydrate
Phenol (2.07 g) was added to a solution of sodium methoxide (from 0.51 g sodium) in dry methanol (20 ml) then the solvent was evaporated in vacuo. The sodium phenoxide residue in 1,2-dimethoxyethane (160 ml) was treated with 2-chloro-4-(4-formylpiperazino)pyrimidine (5.0 g) and heated under reflux for 24 hours. The solvent was evaporated in vacuo and the residue partitioned between chloroform (50 ml) and water (30 ml). The aqueous layer was extracted with chloroform and the combined chloroform extracts were dried (Na 2 SO 4 ) and evaporated in vacuo. The residue was triturated with diethyl ether and the resulting solid re-crystallized from ethyl acetate to give 2-phenoxy-4-(4-formylpiperazino)pyrimidine 1/4 hydrate (2.93 g) m.p. 149°-151° C.
Analysis %: Found: C,62.0; H,5.8; N,19.7. Calculated for C 15 H 16 N 4 O 2 .1/4H 2 O: C,62.4; H,5.8; N,19.4.
iii. 2-Phenoxy-4-piperazinopyrimidine
2-Phenoxy-4-(4-formylpiperazino)pyrimidine (2.6 g) in methanol (27 ml) and 2N hydrochloric acid (6.9 ml) was left at room temperature for 24 hours and then heated on a steam bath for 30 minutes. The solvent was evaporated in vacuo and the residue re-crystallized twice from isopropanol to give 2-phenoxy-4-piperazinopyrimidine (1.5 g) characterized spectroscopically, and used directly.
PREPARATION B
2-dimethylamino-4-piperazinopyrimidine, dihydrochloride 3/4 hydrate ##STR48##
i. 2-Chloro-4-(4-formylpiperazino)pyrimidine (5.0 g) and dimethylamine (7.8 ml, 33% solution in ethanol) in ethanol (70 ml) were heated under reflux for 8 hours. The solvent was evaporated in vacuo and the residue was partitioned between chloroform and water. The aqueous layer was extracted twice with chloroform and the combined chloroform layers dried (Na 2 SO 4 ) and evaporated in vacuo. The residue was re-crystallized from ethyl acetate to give 2-dimethylamino-4-(4-formylpiperazino)pyrimidine (2.7 g), m.p. 116° C.
Analysis %: Found: C,55.9; H,7.2; N,29.5. Calculated for C 11 H 17 N 5 O: C,56.1; H,7.3; N,29.8
ii. This product (2.5 g) in methanol (31 ml) and 2N hydrochloric acid (8 ml) was stirred at room temperature for 2.25 hours and then heated on a steam bath for 2.25 hours. The solvent was evaporated in vacuo and the residue crystallized from ethanol to give 2-dimethyl-amino-4-piperazinopyrimidine, dihydrochloride, 3/4 hydrate m.p. 260°-270° C.
Analysis %: Found: C, 41.0; H, 6.9; N, 24.0. Calculated for C 10 H 17 N 5 .2HCl.3/4H 2 O: C, 40.9; H, 7.0; N, 23.9.
PREPARATION C
2-Hydroxy-4-piperazinopyrimidine, dihydrochloride
2-Chloro-4-(4-formylpiperazino)pyrimidine (5.0 g) in 2N hydrochloric acid (17 ml) was stirred at room temperature for 2.25 hours and then heated on a steam bath for 2.25 hours. The solvent was evaporated in vacuo and replaced by 6N hydrochloric acid (30 ml). The solution was heated on a steam bath for 2.5 hours and then evaporated in vacuo. T.L.C. indicated reaction was still incomplete and therefore the residue in concentrated hydrochloric acid (30 ml) was heated on a steam bath for 3 hours and then evaporated in vacuo. The residue crystallized from methanol to give 2-hydroxy-4-piperazinopyrimidine, dihydrochloride (2.3 g), m.p.>250° C.
Analysis %: Found: C, 37.6; H, 5.7; N, 21.9. Calculated for C 8 H 12 N 4 O.2HCl: C, 38.0; H, 5.6; N, 22.1.
PREPARATION D
4-Chloro-6-isopropoxy-pyrimidine ##STR49##
A solution of sodium isopropoxide (prepared from 0.77 g sodium) in isopropanol (230 ml) was added dropwise over 8 hours to a stirred solution of 4,6-dichloropyrimidine (5.0 g) in isopropanol (60 ml) at room temperature. The solvent was evaporated in vacuo, the residue taken up in water and extracted three times with diethylether (3×70 ml). The combined ether extracts were dried (Na 2 SO 4 ) and evaporated in vacuo to give 4-chloro-6-isopropoxy pyrimidine (4.4 g) as an oil, characterized spectroscopically, and used directly.
PREPARATION E
3-Isopropoxy-6-piperazinopyridazine ##STR50##
3-Chloro-6-piperazinopyridazine (4.0 g) [J. Med. Chem., 5, 541 (1963)] and sodium isopropoxide, prepared by addition of sodium (0.7 g) to dry isopropanol (70 ml), were heated in a bomb at 130°-140° C. for 10 hours. The solvent was evaporated in vacuo, the residue taken up in methylene chloride (300 ml) and the resulting solution washed with water (2×50 ml). The organic extract was dried (Na 2 SO 4 ) and evaporated in vacuo to give 3-isopropoxy-6-piperazinopyridazine (3.3 g). A sample in ethyl acetate, was converted to the maleate salt by treatment with maleic acid in ethyl acetate. The resulting solid was re-crystallized from ethanol, m.p. 144°-145° C.
Analysis: Found: C,49.1; H,5.7; N,11.7 Calculated for C 11 H 18 N 4 O.2C 4 H 4 O 4 .1/2H 2 O: C,49.2; H,5.9; N, 12.1.
PREPARATION F
Preparation of 4-(6-hydroxypyridazin-3-yl)piperazine, hydrobromide ##STR51##
4-(6-Methoxypyridazin-3-yl)piperazine (7.2 g) (J. Med. Chem. 1963, 5, 541) in 48% hydrobromic acid (140 ml) was heated at 110°-120° for 11/2 hours, left at room temperature overnight, then heated at 120° for a further 1 hour. The solvent was evaporated in vacuo and the residue treated twice with isopropanol and evaporated to dryness. The resulting solid was triturated with diethyl ether, filtered and washed with ether to give 4-(6-hydroxypyridazin-3-yl)piperazine, hydrobromide (11.2 g). A sample re-crystallized from ethanol had m.p. 289°-291°.
Analysis %: Found: C,36.8; H,5.0; N,21.4 Calculated for C 8 H 12 N 4 O.HBr: C,36.8; H,5.0; N,21.5.
PREPARATION G
Preparation of 4,6-diethoxy-2-piperazino-1,3,5-triazine ##STR52##
(a) 4,6-Dichloro-2-(4-formylpiperazino)-1,3,5-triazine
1-Formylpiperazine (5.0 g) in dry acetone (28 ml) was added dropwise to a stirred suspension of cyanuric chloride (6.2 g) and sodium bicarbonate (2.58 g) in dry acetone (153 ml) at -35°. The reaction mixture was stirred at -30° for 13/4 hours. Insoluble material was removed by filtration and washed with acetone. The combined filtrate and washings were evaporated in vacuo and the residue taken up in methylene chloride, filtered and the filtrate evaporated in vacuo. The resulting solid was re-crystallized twice from ethyl acetate to give in two fractions 4,6-dichloro-2-(4-formylpiperazino)1,3,5-triazine (3.1 g) m.p. 163°-165°.
Analysis %: Found: C,36.5; H,3.4; N,27.1. Calculated for C 8 H 9 Cl 2 N 5 O: C,36.7; H,3.5; N,26.7.
(b) 4,6-diethoxy-2-(4-formylpiperazino)-1,3,5 triazine
A solution of sodium ethoxide in dry ethanol (prepared from 1.76 g sodium in 100 ml ethanol) was added dropwise to a stirred suspension of 2,4-dichloro-6-(4-formylpiperazino)-1,3,5-triazine (10 g) in dry ethanol (740 ml). The reaction mixture was stirred at room temperature for 6 hours. The solvent was evaporated in vacuo and the residue partitioned between methylene chloride and water. The organic layer was separated, washed 3 times with water, dried (Na 2 SO 4 ) and evaporated in vacuo to give a solid (7.2 g). Re-crystallization from ethyl acetate gave 4,6-diethoxy-2-(4-formylpiperazino)-1,3,5-triazine (6.6 g), m.p. 106°-108.5°.
Analysis %: Found: C,51.3; H,6.8; N,24.7. Calculated for C 12 H 19 N 5 O 3 : C,51.2; H,6.8; N,24.9.
(c) 4,6-Diethoxy-2-piperazino-1,3,5-triazine
The product from (b) (3.25 g) in potassium hydroxide solution (1N, 20 ml) and ethanol (30 ml) was left at room temperature for 3 hours. Then further potassium hydroxide solution (20 ml) was added. After 45 minutes the reaction mixture was extracted with chloroform (5×30 ml), and the combined chloroform extracts dried (Na 2 SO 4 ) and evaporated in vacuo to give 4,6-diethoxy-2-piperazino-1,3,5-triazine (3.0 g) as an oil. The product was characterized spectroscopically and used directly without further purification.
PREPARATION H
Preparation of 3-Phenoxy-6-piperazinopyridazine ##STR53##
Phenol (39.8 g) was treated with a solution of sodium methoxide in methanol (prepared from 0.7 g sodium in 60 ml dry methanol) and the solvent evaporated in vacuo. 3-Chloro-6-piperazinopyridazine (4.0 g) was added to the resulting mixture of sodium phenate and phenol and the mixture heated at 125°-130° for 10 hours with stirring. Methylene chloride (200 ml) was added to the cooled reaction mixture and the solution was washed with aqueous sodium hydroxide solution (3×60 ml, 10%). The organic layer was dried (Na 2 SO 4 ) and evaporated in vacuo. The residue was taken up in isopropanol, treated with charcoal, filtered through "Hyflo" and evaporated in vacuo. Chromatography of the residue on silica ("Keiselgel H", 15 g) eluting with chloroform gave 3-phenoxy-6-piperazinopyridazine (2.0 g). A sample re-crystallized from ethyl acetate as the hemihydrate, m.p. 96°-97°.
Analysis %: Found: C,63.1; H,6.2; N,21.4. Calculated for C 14 H 16 N 4 O.1/2H 2 O: C,63.4; H,6.5; N,21.1.
PREPARATION I
Preparation of 4-chloro-6-(6,7-dimethoxy-1,2,3,4-tetrahydroisoquinol-2-yl)pyrimidine
Sodium hydroxide solution (80 ml, IN) was added to a suspension of 6,7-dimethoxy-1,2,3,4-tetrahydroisoquinoline hydrochloride in water (20 ml) followed by 4,6-dichloropyrimidine (5.95 g) and the mixture was heated on a steam bath for 5 hours. The solvent was evaporated in vacuo to give a brown oil which solidified on standing. Re-crystallization from aqueous ethanol followed by isopropanol gave 4-chloro-6-(6,7-dimethoxy-1,2,3,4-tetrahydroisoquinol-2-yl)pyrimidine (6.0 g). An analytical sample re-crystallized from isopropanol, m.p. 88°-89°. | 2,4-Diaminoquinazoline compounds of the formula ##STR1## or a pharmaceutically acceptable salt thereof wherein R is a pyrimidinyl, pyrazinyl, pyridazinyl or triazinyl group linked to the piperazine ring by one of its carbon atoms, and optionally substituted by hydroxy, halogen, alkyl, aralkyl, alkoxy, aralkoxy,alkylthio, aryl, aryloxy and certain amino groups; their use as an antihypertensive agent and pharmaceutical compositions containing them. | 2 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to a method and apparatus for permanent disposal of hazardous waste and more particularly, to a method and apparatus for permanent disposal of hazardous waste using a borehole extending through a geopressured formation.
2. CROSS REFERENCE TO RELATED APPLICATION
The disclosure of this application is related to my prior application having the same title, now all abandoned, as follows:
______________________________________Ser. No. Filing Date______________________________________06/468,842 June 20, 198306/621,518 June 18, 198407/018,757 February 24, 198707 147/040 January 20, 1988______________________________________
3. DESCRIPTION OF THE PRIOR ART
Permanent disposal of hazardous waste, such as flammables, heavy metals, acids and bases and synthetic organic chemicals present difficult problems. The difficulties are especially acute in disposal of heavy metals (radioactive) waste. Many methods have been developed to provide a proper and safe disposal of hazardous waste without contaminating our natural resources. Various disposal methods include landfills, injection wells, incineration, ocean dumping, wastes exchange, and destruction through organisms ("superbug" method).
U.S. Pat. No. 4,335,978 to Mutch discloses a land fill disposal system. Rather than relying upon the subsurface formation itself to prevent fluid migration, a pair of spaced impermeable liners are employed to prevent fluid migration. The disclosed land fill is located above rather than below the subsurface water table for the area to preclude contamination.
Haynes et al U.S. Pat. No. 4,377,509 is entitled "Packaging for Ocean Disposal of Low-Level Radioactive Waste Material". A plurality of conventional 55 gallon metal drums are filled with the nuclear waste material and placed within a concrete shell. A filler material of asphaltic or a dry portland cement concrete is then used to fill the shell. Immediately prior to dumping in the ocean, water is introduced into the shell to activate the cement. In an alternate embodiment, the concrete is allowed to harden before dumping into the ocean.
U.S. Pat. No. 4,377,167 to Bird et al discloses two improved container materials for solid waste materials at an underground impervious stable rock formation. The prior practice had been to rely upon the insolubility of the radioactive elements to prevent migration of the radioactive waste material rather than containing the waste for a sufficient period of time to effect decay within the container. Bird's invention resides in forming a container out of a naturally occurring nickel alloy having proven superior aging characteristics.
The Upermann U.S. Pat. No. 4,316,814 is entitled "Seal For A Storage Borehole Accommodating Radioactive Waste and Method of Applying the Seal". The storage waste containers are lowered into the borehole formed in a salt formation in a stacked relationship. The seal of the borehole above the stored material prevents escape of the radioactive waste up the borehole.
The Klingle et al U.S. Pat. No. 4,252,462 is entitled "Chemical Land Fill" for disposal of waste water sludge. An impoundment area having a liquid impervious base and a perimeter dike is arranged to receive the waste water liquid therein. The sludge is dewatered and subsequently covered with an impervious layer.
The following patents to Gablin et al disclose systems for disposing of nuclear reactor effluent having mixed liquid and particulate matters: U.S. Pat. Nos. 4,196,169, 4,168,243, 4,056,362, 4,167,491, 3,986,977.
Geologists have characterized subsurface rock formations forming the earth's crust in various ways. One such classification has been to divide sedimentary rocks into two broad groups based on their pore-fluid pressures. These two mutually exclusive groups are labeled (1) hydropressures and (2) geopressures, and will be defined in this application as such. Hydropressure zones or formation have pore fluid pressures that are created by the effective weight of the overlying waters plus the back pressure of out-flowing waters. Geopressure formations or zones are created where the hydropressure rock is sealed in a confined geological container (geopressure cell) and is subjected to a geostatic pressuring source greater than hydropressures. The geostatic pressuring force source is the weight and temperature of the earth's crust with depth of burial. A classic example of a hydropressure-geopressure province is the Gulf of Mexico Salt Basin, which includes the Texas-Louisiana Cenzoic Salt Basin.
Hydropressure formations have leaks which enable flow or migration of the fluid pressure so over time they adjust to the hydropressure pressure for the depth. This is commonly referred to as normal pressure. Unlike hydropressures or hydropressure formations, geopressure formations are sealed. A geopressure seal is defined as a restriction to flow such that geopressures have not been dissipated between the time they were created in the geologic past and the present. By definition all geopressures or geopressure formations must have a geopressure seal. The block of the earth's crust that is sealed off and contains the geopressures is called a geopressure cell which is the definition adopted herein. To create a geopressure cell (a confined or enclosed container or reservoir), the surrounding earth crust formations must be effective as a seal at the top, bottom and all sides of the cell.
The geopressure cells or formations are sealed in regional fault blocks by shale layers and regional fault growths. Porosity is preserved in geopressure formation or zones due to the pore fluid pressure which is greater than the hydropressure for the same depth. They are sometimes called or referred to as abnormally high-pressure zones or formations in the petroleum industry.
For an in depth description of hydropressure geopressure formations and their characteristics and properties, see the article "Geopressures" by Charles A. Stuart which appears in the Supplemental Proceedings of the Second Symposium on Abnormal Subsurface Pressure presented Jan. 30, 1970 at Louisiana State University in Baton Rouge, La.
The encountering of geopressure zones when drilling for hydrocarbons or minerals presented substantial problems. In U.S. Pat. No. 3,399,723, to Charles A. Stuart (class 166 subclass 4) those drilling problems associated with encountering a geopressure formation are addressed, but not for the purpose of the present invention. From the standpoint of describing the present invention both hydropressure and geopressure formations are defined and explained at length in the Stuart patent. The problem of encountering the abnormally high pressure of the geopressure zone when the geopressure barrier seal (the transition or mutation zone) is broken or penetrated by the drill bit is described as a kick and the parameters of accommodating that pressure transition are addressed.
All of the above specifically mentioned or identified U.S. patents and the C. A. Stuart published article are hereby fully and specifically incorporated herein for forming part of applicant's written description as if their content had been set forth in full.
IDENTIFICATION OF THE OBJECTS OF THE INVENTION
An object of the present invention is to provide a method for disposing hazardous waste in a borehole extending into a subsurface geopressured formation or cell.
It is another object of this invention to provide a method that will provide for permanent safe disposal of radioactive and/or other hazardous waste in boreholes formed in geopressure formations.
Another object of this invention is to provide a disposal method where sealed containers filled with hazardous waste are encased within a subsurface geopressured formation to prevent waste migration in the event of container failure.
A further object of the present invention is to provide a method of disposal of hazardous waste by hydraulically injecting hazardous waste into the pores of a geopressured formation or cell to trap the waste within the geopressured formation.
SUMMARY OF THE INVENTION
The present invention relates to a method for permanently disposing hazardous waste in a borehole extending through a sealed, non-migrating geopressured formation. In one embodiment the waste is sealed in an elongated container which is lowered down the borehole to concentrically position the containers in a stacked relationship in the borehole within a geopressured formation. The stacked containers are then completely encased within the borehole for restoring the geopressure formation seal.
A second embodiment of the method for disposing hazardous waste in a borehole extending through a non-migrating geopressured formation includes pumping the dissolved or entrained hazardous waste down the borehole and injecting the waste through perforations in the casing into the pores of the geopressured formation. The pressurized hazardous waste may fracture the geopressured formation and upon reduction in the pressure the waste is trapped in the geopressured formation which is then resealed to restore its geopressure characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages, and features of the invention will become more apparent by reference to the drawings which are appended hereto and where like numerals indicate like parts, and wherein an illustrated embodiment of the invention is shown, of which:
FIG. 1 is an elevational view in section of a permanent storage borehole of the present invention extending into a sealed geopressured subsurface formation or cell;
FIG. 2 is an elevational view in section, of an elongated container apparatus for receiving the waste that is permanently stored in a borehole formed in the geopressure zone; and
FIG. 3 is a fragmentary elevational view, in section, of a second embodiment of a borehole of the present invention in which the hazardous waste is placed within the geopressure formation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A permanent storage or disposal well or borehole, generally designated 10, employed in the present invention, is illustrated in FIG. 1, that extends from the earth surface S into the earth's crust C. The borehole 10 may be formed by any suitable known method of drilling the crust C. The borehole 10 typically includes, in sequence from outside to inside, a tubular conductor casing 12, a surface casing 14, a protective casing 16, a protective liner 18 (supported from casing 16), and an inner casing 20. As is known, the various well tubular conduits are arranged concentrically and extend to various subsurface depths with the smaller conduits extending to the greater depths in the crust C. While the illustrated casing arrangement may be suitable for some locations, those skilled in the art will appreciate the casing program actually used will depend on numerous factors and may be varied from that disclosed without departing from the present invention. Part or all of the casing may be rendered permanent by cementing in place as illustrated. However, it will be understood that the fully cemented condition illustrated in FIG. 1 is not achieved until the hazardous waste has been properly placed or positioned using the bore hole 10.
Disposed within the inner casing 20 are a plurality of substantially identical elongated closed containers, referenced from top to bottom 22, 24, 26, and 28 for receiving the hazardous material. Containers 24 and 26 are illustrated stacked vertically in tandem, but FIG. 1 is broken between containers 22 and 24 and containers 26 and 28 so as to schematically illustrate any desired number or plurality of containers 22, 24, 26, and 28 to be disposed or located in the casing 20. Those skilled in the art will also appreciate any suitable equivalent safe container for the hazardous waste to be disposed of in the borehole may be used. The material and configuration of the containers is a matter of design choice as long as they may be safely placed in the borehole 10 at the desired location by passing within the tubular casing.
It is preferred that the containers be disposed concentric with the longitudinal axis of the inner casing 20 to aid in proper surrounding concentric encasement and storage of the containers 22, 24, 26 and 28 by concrete. Referring to lowermost container 28, a substantially concentric annulus is formed between the inwardly facing surface 30 of the inner casing 20 and the outwardly facing surface 32 of the container 28 which is filled with cement which then hardens in place. Various types of centralizers (not illustrated) may be used to hold the containers 22-28 in the concentric position during cementing.
Turning now to FIG. 2, the elongated container 28, which is typical of the plurality of containers 22, 24, and 26, forms a waste material storage cavity or interior 34 and includes a sealing or closure cap 36. In the preferred embodiment the container 28 is vitrified to ensure that the container 28 will not rapidly decay with the passage of time.
The seal cap 36 is threadedly secured at the upper end 38 of the container 28 and provides a fluid seal for preventing leakage of hazardous waste from the interior 34 of the container 28. In the preferred embodiment the seal cap 36 has outwardly facing helical pin threads 40 and the container 28 has complementary inwardly facing helical box threads 42 for securing the sealing the cap 36 with the container 28. The container 28 is preferably sealed with the seal cap 36 a the waste processing or generation site for safe transportation to the disposal well 10.
The hazardous waste is sealed within the container 28 which is preferably formed in lengths of 30 ft to 60 ft and outside diameters of 5 to 6 inches. Such outside diameter allows the container 28 to be lowered into the borehole 10 through inner casing 20 which is somewhat larger in inside diameter to provide a desired radial clearance. The storage containers 28 are lowered in the borehole 10 until they are positioned or stacked for permanent safe disposal within a geopressured zone 48 which will be described in greater detail hereinafter.
In FIG. 3 a fragmentary elevational view of the second embodiment of the hazardous waste disposal borehole of the present invention is illustrated which injects the hazardous material directly into the pores of the geopressured formation or zone. The hazardous waste may be entrained or in solution in the carrier hydraulic fluid. In the second embodiment, like reference characters, but increased by a factor of 100, will be used to designate like parts. The inner casing 120 is positioned in the borehole 110 similar to the bottom of inner casing 20 positioned in borehole 10 in FIG. 1, but the casing 120 is not cement filled to provide a flow passageway from the earth's surface. The inner casing 120 has a plurality of perforations 144 and 146 extending therethrough which communicate with the surrounding geopressured formation 148. The geopressured formation 148 is hydraulically split or fractured 150 by pressurized hazardous waste liquid directly injected through perforations 144 and 146 into the pores the geopressured formation 148.
USE AND OPERATION
In the use and operation of the preferred embodiment, a borehole 10 extending through a hydropressure zone 47 into geopressured formation 48 is formed or drilled and suitably cased. The present invention encompasses use of existing boreholes 10 drilled for oil, gas, or geothermal exploitation, which have been drilled through hydropressure zones 47 into geopressured formations 48. If needed, new boreholes or existing boreholes could be drilled deeper to provide the desired storage cavity in a geopressured zone 48. The hydropressure and geopressure formations 47 and 48 are separated by the mutation or transition zone 50 that forms the upper seal for the geopressure cell, formation or zone 48. The geopressure seal formed by the transition zone 50 is penetrated when forming the borehole 10, but care should be taken not to disturb any other seal of the geopressure formation or cell. The casing adjacent the transition zone 50 may be permanent or temporary (recoverable), but should not interfere with rescaling of the geopressure formation 48.
While geopressured formations or zones are well known and easily recognized to those skilled in the art as abnormally high pressure zones, a brief explanation or review of such special formations may be useful to appreciating the present invention. Geopressured formations are characterized by abnormally high interstitial or pore fluid pressures existing in subsurface formations. Geopressure formations or zones come into being due to geostatic compaction by overlaying sediments which action eventually produces a pressure seal transition zone that prevents fluids from leaving the geopressure cell or formation, thereby resulting in abnormally high interstitial or pore fluid pressure from the geostatic pressure. The geopressure seals are extremely old and unlikely to be disturbed by natural geological changes such as earthquakes.
Abnormally high interstitial pressure is defined in relation to normal or hydrostatic pressures for the location or depth of the subsurface formation. Normal pressures are those exerted by a column of naturally occurring water between the surface of the earth and the depth at which the pressure is being measured (the hydrostatic head). A hydropressure formation system with normal pressure is termed an open system that enables migration of the liquid to normalize pressure. Naturally occurring waters vary in density equivalent ranging from 0.433 psi/ft to 0.465 psi/ft. Thus a normal hydrostatic pressure, in a hydropressure formation will vary with depth (the hydrostatic head). Hazardous waste, if composed of heavy dense metal molecules, as with nuclear waste, tend to segregate to levels lower than the natural interstitial water. In a sealed geopressure cell or zone, the lower geopressure seal will contain that internal migration since the lower or bottom seal is not disturbed in forming the borehole 10. At any rate, assuming a geopressure zone seal 50 is penetrated or breached at 7,000 ft, and further assuming escaped water does actually migrate towards the surface of the earth, the driving gradient would be quickly dissipated, and very little real movement of the hazardous waste would occur. Furthermore, since the radiation level of the nuclear waste declines to harmless levels within 400 years (McGraw Hill Encyclopedia of Engineering, 1982, Parker, Cybil, Editor, page 885) danger of contamination from escaping radiation is virtually non-existent. Additionally if the hazardous waste is contained within a steel and concrete cased borehole below the reestablished upper geopressure seal, as disclosed in the present invention, there would be a further assurance against leakage.
At the well or borehole 10, the waste filled elongated containers 22, 24, 26, 28 are moved down lowered individually into the borehole 10 by wireline until positioned within the geopressured formation 48. The containers are stacked or placed in a tandem relationship concentric with the casing 20 as shown in FIG. 1. In most deep boreholes, approximately 14,000 to 25,000 ft. in depth, 5,000 ft to 10,000 ft of elongated containers 22, 24, 26, and 28 may be lowered into the borehole 10 and still remain within the geopressured formation.
The containers 22, 24, 26 and 28 are then encased within the borehole 10 by cementing the interior of casing 20 back to the surface S of the earth. The metal casing adjacent the geopressure zone seal 50 is preferably removed prior to encasement to avoid forming a leak path when the metal corrodes. This encasement would be performed to insure permanent safety in the permanent disposal of the hazardous waste. This encasement also restores the seal 50 of the geopressure zone 48 to prevent migration up the borehole 10. The preferred embodiment uses a cement mixture to encase the containers 22, 24, 26 and 28 but other types of encasing mixtures or compositions could be used. The resultant relatively small column of containers 22, 24, 26 and 28 enables heat and radiation to dissipate into the relative large volume of sediments and trapped non-migrating salt water to provide a final or safe permanent disposal of the hazardous waste.
The second embodiment for a method for disposal of hazardous waste as illustrated in FIG. 3 is especially well suited for low permeability geopressure zones. A well casing 120 in the borehole 110 is perforated at 144 and 146. By pressurizing the hydraulic waste including entrained or suspended solids to move down the bore of casing 120 from the surfaces through the perforations 144 and 146 the hazardous waste is forced to flow into and thereby fracture the geopressured formation 148. When the injection pressure on the hazardous waste is reduced, the fractures close and the solid and liquid waste material is trapped in the geopressured formation 48. The waste fluid bleed into local sections increasing the pressure within the geopressure zone slightly and the entrained solids are trapped and held permanently within the formation. Thus the hydraulic fracture technique can be used for emplacement of both liquid waste and sand grain sized solid waste.
Hydraulic fracture technology has been used in the oil industry for enhancement of recovery of hydrocarbons. Such procedures create formation fractures through very intense hydraulic pressure applied by pumps at the surface S of the earth's crust C and transmitted to the geopressure formation 50 through the casing 120 in the borehole 110. The resulting hydraulic formation fractures are of small width, usually 2 inches or less, which grow in vertical height, 100 ft to 1000 ft, and radial penetration of 200 ft to 2000 ft from the point of fracture initiation at the perforations 44 and 46, but can hold relatively large volumes of fluids and entrained solids.
After injection of the hazardous material into the geopressure zone 148 the borehole is sealed with concrete to reestablish the geopressure zone seal 50 and prevent migration up the borehole 10.
It will be appreciated that to maximize the disposal in a particular geopressure cell or formation, that both disclosed embodiments may be employed sequentially to dispose of the hazardous waste. By sequentially it should be understood that the containers may be placed in the borehole before or after disposal by pumping.
This is preferably accomplished by filling the entire borehole with cement (FIG. 1), but suitable monitoring passages may be provided above the transition zone. If desired a radioactive barrier of any suitable material such as lead may be used to help reestablish the seal.
Various modifications and alterations in the described apparatus and methods will be apparent to those skilled in the art of the foregoing description which does not depart from the spirit of the invention. For this reason, these changes are desired to be included in the appended claims. Dependent claims recite the only limitation to the present invention and the descriptive manner which is employed for setting forth the embodiments and is to be interpreted as illustrative and not limitative. | A method and apparatus for safely disposing hazardous waste in a borehole extending through a seal for a subsurface geopressured formation wherein sealed elongated containers filled with hazardous waste are lowered in the borehole to be positioned within a geopressured formation where the containers are encased in the borehole. In an alternative embodiment, hazardous waste is disposed in the borehole by pressuring the liquid waste and injecting the waste through perforations in a borehole casing directly into the pores of a geopressured formation. The pressurized liquid fractures the geopressure formation and upon release of the pressure on the waste liquid the waste is trapped in the geopressured formation. The seal of the geopressure formation is then restored for providing safe disposal. | 1 |
FIELD OF THE INVENTION
This invention relates to jewelry, and more specifically to a clasp for use in making articles of jewelry such as bracelets, from flexible strands of decorative cord or like material.
BACKGROUND OF THE INVENTION
Making home-made jewelry has become popular among young women, especially those in their teens and pre-teens. Bracelets, and necklaces, for example, can be made from various materials, such as strands of beads, cords of yarn or plastics, metal chains, and many other materials. Typically, the bracelet or necklace is made up of several, e.g., three or more, such strands arranged in parallel to one another. To connect the opposite ends of the parallel array of strands to each other, each end of the parallel array of strands is typically fastened to a clasp. The two clasps are releasably connectible to each other so that the bracelet or necklace can be conveniently worn and removed.
Typical jewelry clasps are described in the following U.S. Pat. Nos:
U.S. Pat. No. 2,266,074, granted Dec. 16, 1941, U.S. Pat. No. 2,586,758, granted Feb. 19, 1952, U.S. Pat. No. 3,120,042, granted Feb. 4, 1964, U.S. Pat. No. 3,247,560, granted Apr. 26, 1966, U.S. Pat. No. 3,247,561, granted Apr. 26, 1966, U.S. Pat. No. 4,527,316, granted Jul. 9, 1985, U.S. Pat. No. 6,880,363, granted Apr. 19, 2005, and U.S. Pat. No. 8,499,582, granted Aug. 6, 2013.
These clasps provide for connection of the ends of necklaces and bracelets composed of plural strands, but are more suitable for use by adults, and generally lack the ability to accommodate a broad variety of kinds of strands.
There is a need for an inexpensive, versatile, and easy to use clasp to enable young persons to make their own bracelets, necklaces and similar articles.
SUMMARY OF THE INVENTION
The clasp in accordance with the invention comprises an elongated hollow tube having first and second ends, and an opening at least at the first end. The tube is defined by a cylindrical wall having a circumferential outer surface and a Z-shaped slot forming an opening from the interior of the tube to the exterior thereof. The slot extends from the first end of the tube to a location adjacent the second end of the tube.
More specifically, the hollow tube is elongated along a longitudinal direction, and its first and second opposite ends are separated from each other along the longitudinal direction. The tube comprises a circumferential wall having internal and external surfaces, and a longitudinal internal bore defined by the internal surface. The bore has an opening at the first end of the tube, and the bore extends longitudinally from the opening at least to a location adjacent the second end. The slot forms a continuous elongated opening through the wall from the internal surface to the external surface of the wall, and extends from the first end of the tube at least to a location adjacent the second end. The slot has minimum and maximum widths and an entry formed at the first end of the tube. The slot comprises a first slot section extending longitudinally from the entry to a first intermediate location between the first and second ends of the tube, a second section extending from the first intermediate location to a second intermediate location between the first and second ends. The first and second intermediate locations are both closer to the first end than to the second end. A third section of the slot extends longitudinally from the second intermediate location to an end surface at a third intermediate location. The third intermediate location is closer to the second end than to the first end, and the first and third sections are circumferentially displaced from each other.
Plural flexible strands, each having a thickness smaller than the minimum width of the slot and an enlarged end having a thickness larger than the maximum width of the slot, can be slid through the first and second sections into positions in which they extend through the third section of the slot, while their enlarged ends are passed through the opening at the first end of the tube and brought to positions inside the longitudinal internal bore of said tube and adjacent the third section of the slot.
The second intermediate location is preferably at least as close as the first intermediate location to the first end of the hollow tube, and can be closer than the first intermediate location to the first end of the hollow tube so that the second section forms acute angles with the first and third sections.
Preferably each of the three section of the slot is elongated, and the slot has a uniform width.
The end surface of the third section of the slot can be constituted by a closed end of the third section.
A fastening loop can be attached to the external surface of the circumferential wall at a location midway between the first and second ends and diametrically opposite the third section of the slot.
An article of jewelry can be made using two of the above-described elongated hollow tubes and a plurality of flexible strands each having enlargements at both ends for connection to the third slot section of the respective tubes. A releasable connection can be provided to connecting the two tubes to each other in parallel relationship, so that the clasps, the releasable connection and the flexible strands form a closed loop.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique perspective view of a clasp according to the invention, showing a side and one end thereof;
FIG. 2 is an oblique perspective view of the clasp showing the opposite end thereof;
FIG. 3 is an oblique perspective view corresponding to FIG. 2 , illustrating the manner in which a flexible strand is attached to the clasp; and
FIG. 4 is a perspective view showing an assembly composed of two clasps linked together in parallel relationship and an array of flexible strands extending from one clasp to the other to form a bracelet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1 and 2 , the clasp 10 comprises a hollow tube 12 , elongated along a longitudinal direction and having first and second opposite ends, 14 and 16 respectively, separated from each other along the longitudinal direction. The tube comprises a circumferential wall having and internal surface 18 and an external surface 20 , and a longitudinal internal bore 22 defined by the internal surface. The internal bore 22 has an opening at the first end 14 of the tube and extends longitudinally from the opening at least to a location 24 adjacent the second end 16 . In the embodiment shown, the bore 2 extends all the way through the tube, and has openings at both ends. A slot 26 forms a continuous elongated opening through the wall from the internal surface to the external surface. This opening extends from the first end 14 of the tube at least to location 24 adjacent the second end 16 of the tube.
The slot can be of uniform width, but the width of the slot does not need to be strictly uniform. Thus, the slot may have a minimum width and a maximum width. The slot has an entry 28 formed at the first end 14 of the tube, and comprises a first slot section 30 , extending longitudinally from the entry 28 to a first intermediate location 32 between the first and second ends of the tube, a second section 34 , extending from the first intermediate location 32 to a second intermediate location 36 between the first and second ends of the tube, and a third section 38 , extending longitudinally from the second intermediate location 36 to an end surface at location 24 , which is a third intermediate location.
The first and second intermediate locations 32 and 36 are both closer to the first end 14 of the tube than to the second end 16 , and the third intermediate location 24 is closer to the second end 16 of the tube than to the first end 14 .
Because the first and third sections of the slot 30 and 38 are circumferentially displaced from each other and connected by the second section 34 , the slot is Z-shaped. Preferably the shape of the slot is such that the second intermediate location 36 is at least as close as the first intermediate location 32 to the first end 14 of the tube. If the distance from intermediate location 32 to end 14 of the tube exceeds the distance from intermediate location 36 to the end 14 of the tube by the width of the second slot section 34 , the intermediate section 34 of the slot can be strictly circumferential. Ideally, however, the second intermediate location 36 is still closer than the first intermediate location 32 to said first end 14 of the tube, so that the first and third sections 30 and 38 form acute angles, e.g., angles of about 80°, with the second section 34 , as shown in FIGS. 1 and 2 .
In FIG. 2 , a flexible strand 40 , is shown being engaged with the slot 26 . In this case, the flexible strand 40 is a length of flexible plastics material having an oblong rectangular cross-sectional shape and a width, measured in the direction of smaller dimension of the rectangular cross-section, that is smaller than the minimum width of the slot 26 . A simple overhand knot 42 is formed at an end of the flexible strand 40 so that the strand has an enlarged end with a thickness larger than the maximum width of the slot 26 . As shown in FIG. 3 , the strand is slid through the entry 28 and through the first section of the slot into the second section, with the enlarged end formed by the knot positioned so that the strand extends from the exterior of the tube, inwardly through the slot, to the enlarged end. The strand can then be moved into the third section of the slot, and the enlarged end can be pulled inward through the opening at the first end 14 of the tube. By manually bending the strand 40 so that it passes around the acute angles of the slot, the strand 40 can be slid into a position adjacent a similar strand 44 previously engaged with the tube in a similar manner. A series of strands can be engaged with the tube until the third section 38 of the slot is filled, or nearly filled. The enlarged ends of the strands, which are larger than the maximum width of the third section 38 of the slot, are positioned inside the bore of the tube adjacent the third slot section 38 , and prevent the strands from being pulled out through the third slot section.
The second slot section 34 , which extends from slot section 38 to slot section 30 , which is circumferentially displaced from slot section 34 , prevents inadvertent disengagement of the strands from the tube by requiring, for removal, a special manipulation of the strands in which they are moved longitudinally from slot section 38 into slot section 34 , and then through slot section 34 to slot section 30 in a direction having a circumferential component. Thus when the strands are in place, they are confined between the second section 34 of the slot, and the closed end surface of the third slot section at the third intermediate location 24 , and inadvertent removal of the strands form the slot is effectively prevented.
The strands, of course, need not be plastic strands having elongated rectangular cross-sectional shapes. Lengths of yarn having knotted ends, or any of various other kinds of strands, for example, beaded strings or beaded chains, can be used. In the case of a beaded string or chain, an endmost bead can serve as the enlargement at the end of the strand, that prevents the strand from being pulled out through the third slot section 38 . The Z-shape of the slot will prevent accidental disengagement of the strands from the tubular clasps.
Although the third section 38 of the slot in the embodiment shown in FIGS. 1-4 has a closed end at location 24 , the advantages of the invention can be realized in alternative embodiments in which the slot has entries at both ends of the tube, two first slot sections corresponding to slot section 30 adjacent the opposite ends of the tube, two second slot sections corresponding to slot section 34 , and a single third slot section corresponding to slot section 38 . In this case, the end surfaces that limit longitudinal sliding of the strands, are side walls of the two second slot sections instead of closed ends corresponding to the closed end of slot section 38 at location 24 .
FIG. 3 also shows a fastening loop 46 attached to the external surface of the circumferential wall of the tube at a location preferably midway between the first and second ends 14 and 16 of the tube and diametrically opposite the third slot section 38 .
As shown in FIG. 4 , two clasps 48 and 50 , of the kind illustrated in FIGS. 1-3 , can be utilized to make a bracelet. The fastening loops 52 and 54 of the respective clasps can be connected to each other by a link 56 composed of two integrally connected, resilient, wire loops 58 and 60 , having gaps 62 and 64 , which have a width slightly smaller than the width of the wire of the loops. The resilience of the link and the dimensional relationship of the gaps to the loop wire allow the link to be snapped onto the loops, and to be disengaged from the loops manually.
As mentioned above, the slotted tubular clasps as described above can be used to make bracelets from a wide variety of materials. The size of the bracelet depends on the lengths of the strands that extend from one clasp to the other. With sufficiently long strands of material, the clasps can also be used to make necklaces and even decorative belts. The clasps can be used to make an article of jewelry using two or more strands of different kinds of material, for example a bracelet made from strands of beads and yarns disposed side-by-side in an alternating arrangement.
The clasps can also be re-used. For example, if the strands of an article of jewelry made from a pair of clasps are damaged, or the user simply desires to make a new article of jewelry, she can easily remove the existing strands and replace them with new strands, strands of other materials, or strands of a different length. | A clasp for use in making jewelry comprises an elongated hollow tube having an opening at least at one of its ends and an elongated, Z-shaped slot having a first section extending from the open end of the tube to a first intermediate location, a second section extending approximately circumferentially from the first intermediate location to a second intermediate location, and a third section extending from the second intermediate location to a third intermediate location. Flexible decorative strands of material, having enlarged ends larger than the slot, can be slid into the opening of the slot and into the third section, where they remain unless deliberate manipulations are undertaken to remove the strands. | 0 |
FIELD OF THE INVENTION
The present invention relates to a multi-layer board used in small electronic equipment such as a portable telephone.
BACKGROUND OF THE INVENTION
As shown in FIG. 4 , a conventional multi-layer board is formed with resin layers. For example, on a first surface 1 , a patterned is formed, and an electronic component 2 is mounted. The electronic component 2 is conducted to a second surface 4 , third surface 5 or fourth surface 6 with a through hole 3 in order to be connected to a component such as an inductor formed on the surface 4 , 5 or 6 . Intervals between any of the first surface 1 through the fourth surface 6 are filled with a resin 7 .
The conventional multi-layer board consisting of the resin layers, upon having the inductor formed thereon, shrinks with heat due to a temperature change, thus causing a characteristic such as an inductance to vary.
SUMMARY OF THE INVENTION
A multi-layer board has mechanical and electric characteristics stabilized against a temperature change. The multi-layer board includes a ceramic layer, a resin layer disposed over the ceramic layer, and a impedance element formed on the ceramic layer. The resin layer may be have an electronic component mounted thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a multi-layer board in accordance with a first exemplary embodiment of the present invention.
FIG. 2 is a perspective view of an essential part of the multi-layer board in accordance with the first embodiment.
FIG. 3 is a sectional view of a multi-layer board in accordance with a second exemplary embodiment of the present invention.
FIG. 4 is a sectional view of a conventional multi-layer board.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(Exemplary Embodiment 1)
In FIG. 1 , a ceramic layer 11 having a relative dielectric constant of about 10 (at 1 MHz), has a top surface (a third surface) 11 a provided with a resistor 12 , inductor 13 and capacitor 14 formed thereon. The layer 11 has a bottom surface (a fourth surface) 25 a provided with a resistor 15 , inductor 16 , and capacitor 17 formed thereon. These impedance elements, since being formed on both surfaces of the ceramic layer 11 , are stable against an external temperature change.
A Resin layer 18 having a relative dielectric constant of about 4 (at 1 MHz) has a top surface (a second surface) 18 a provided with a pattern 19 formed thereon. The pattern 19 is conducted to the third surface 11 a with an interstitial via-hole (hereinafter referred to as a hole) 20 and to a first surface 22 a with a hole 21 to be connected to circuits. Since the relative dielectric constants of resin layers 18 , 22 are lower than that of ceramic layer 11 , a strip line formed on the second surface 18 a can be wide, thereby having a reduced loss. This is preferable particularly in high frequency performance for improving a noise factor (NF).
The resin layer 22 having a relative dielectric constant of about 4 (at 1 MHz) has a top surface (a first surface) 22 a provided with a surface-mounted device (SMD) 23 and a bare chip device 24 mounted thereon.
The resin layers 25 , 26 each having a relative dielectric constant of about 4 (at 1 MHz) has a fifth surface 26 a provided with a pattern 27 formed thereon. The pattern 27 is conducted to a fourth surface 25 a with a hole 28 and to a sixth surface 26 b with a hole 29 to be connected to circuits. The hole 29 is a through-hole extending from the first surface 22 a to the sixth surface 26 b (from the top external surface to the bottom external surface of the multi-layer board).
Thus, the multi-layer board of the first embodiment has a six-surface structure, that is, includes the ceramic layer 11 as a core board, the resin layers 18 , 22 , 25 , and 26 over both surfaces of the layer 11 . The resistors 12 , 15 and inductors 13 , 16 , since being formed on the ceramic layer 11 , have respective characteristics stabilized against the temperature change, thus having accurately-maintained values.
The first surface 22 a , since being provided with the SMD 23 and bare chip device 24 mounted thereon, contributes to an improved packaging-density, thus enabling the board to be small.
The resin layers 18 , 22 , 25 , and 26 since being stacked over both surfaces of the ceramic layer 11 , 25 , allow the multi-layer board not to warp and to be mounted on a base board of an apparatus without a gap.
In the case that the base board is a resin board, the multi-layer board can be mounted in close contact with the base board if the resin layer, of the multi-layer board, contacting the base board is made of resin having a thermal expansion coefficient close to that of the base board.
FIG. 2 is a perspective view of the impedance elements, the resistor 12 , inductor 13 , and capacitor 14 on the third surface 11 a of the ceramic layer 11 . The resistor 12 and inductor 13 are laser-trimmed, thus having a resistance and inductance adjusted accurately, and thereby having stable performance. In addition, the inductor 13 is formed on the ceramic layer 11 having a large relative dielectric constant, thereby having a large inductance despite its reduced size. Furthermore, as clearly illustrated in FIG. 2 , the inductor 13 is patterned so as to have a spiral shape.
If a portion, of the second surface 18 a , corresponding to inductor 13 is not provided with a ground pattern formed on the surface, the inductor 13 has an increased Q-factor.
The capacitors 14 , 17 include electrode layers 14 a , 14 c , 17 a , and 17 c and dielectric layers 14 b , 17 b which are formed by printing and sintering. The dielectric layers 14 b , 17 b , upon being made of high dielectric material, provide the capacitors 14 , 17 with large capacitances despite their reduced sizes.
(Exemplary Embodiment 2)
As illustrated with a sectional view of FIG. 3 , a multi-layer board in accordance with a second exemplary embodiment includes eight surfaces. Instead of the fifth surface 26 a of the board of the first embodiment, a fifth surface 30 a defined by a polyimide film 30 and a sixth surface 31 a defined by a resin layer 31 are inserted.
In FIG. 3 , the sixth surface 31 a of the polyimide film 30 is provided with a capacitor 32 formed by vapor deposition, so that the capacitor 32 has an accurate capacitance and a low profile.
Each multi-layer board of the first and second embodiments including the ceramic layer resists bending. Further, the multi-layer board is inexpensive since including the stacked resin layers, which are inexpensive. | A multi-layer board includes a ceramic layer and plural resin layers which are stacked together. The ceramic layer is provided with an impedance element formed thereon, and the uppermost resin layer is provided with an electronic component mounted thereon. The multi-layer board is stable against a temperature change. | 7 |
This is a continuation, of application Ser. No. 716,085 filed Aug. 20, 1976, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to delay circuits and more particularly, it relates to a delay circuit utilized in conjunction with an electrically-operated device such as a gas solenoid valve for controlling the operation thereof. The delay circuit of this invention has particular application in industrial plants, manufacturing facilities, restaurants or any other facilities in which gas is utilized for operation of equipment.
Generally, it is known that in the operation of gas operated equipment such as burners, gas ovens and similar types of apparatus, an electrically-operated solenoid valve is frequently utilized for controlling the flow of gas in a main gas line to utilization points. If a plurality of gas-operated equipment is used, they commonly are coupled in series to the main gas line. One common problem encountered in the use of electrically-operated gas valves is that electrically power interruptions, even of the shortest interval, tend to interfere with the safe and convenient operation of the equipment. In such cases of a power failure such as a complete power loss or even a transient in the line voltage which only effects a momentary loss or drop in power, the electrically-operated solenoid valve connected conventionally upstream of the utilization points is caused to close and thus prevents further flow of gas to the individual burners or ovens. After closing of the valve, safety codes generally require that the gas line valve be manually reset. However, the requirement of manual reset for voltage fluctuations of short duration serves no practical purpose from a safety standpoint or otherwise. Complete or temporary power loss may be due to many circumstances such as disturbances on the line from the generating power source being overloaded, overloading by excess number of equipments being placed on the line internally, lightening, or fire and the like.
Regardless of the cause of the power interruption or fluctuation, the solenoid valve in a conventional control system will automatically close unitl a manually-operated reset switch or control device is activated. In many prior art control systems, the gas solenoid valve is closed and no indication of its interruption is known until an individual recognizes that no gas is being supplied to a utilization point. Often the interruption of the operation of the gas equipment may not be noticed for a considerable time after actual closing of the valve. This delay may cause disasterous effects on the cooking operation or other functions being performed by various equipment coupled to the main gas line causing delay, economic loss, and the creation of unsafe conditions. In order to restore the equipment back to normal operation after the power failure, it is necessary for an operator to reactivate each of the devices such as re-lighting each of the pilot lights of the burners and the like.
It should be apparent that it is extremely undesirable to require personnel to go through the laborous and time-consuming process of reactivating the equipment each time there is a mere transient in the line in which a momentary loss or drop in power is encountered in addition to the inherent disadvantages occurring because of the interruption of the operation of the equipment. It is, therefore, desirable to provide a delay circuit for automatically preventing the permanent closing or shutting of the gas solenoid valve when the power loss or fluctuation does not exceed a pre-determined time limit. In addition, it is advantageous to provide a device which will immediately and effectively warn operating personnel that the gas solenoid has been closed due to power interruptions greater than a predetermined interval.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a new and novel delay circuit which has all of the aforementioned features and yet overcomes each and every one of the above-discussed problems.
It is another object of the present invention to provide a delay circuit for automatically preventing the permanent closing or shutting of an electrically-operated device when duration of power loss or fluctuation is less than a predetermined interval.
It is another object of the present invention to provide a control circuit for a device providing visual and/or sound warning of a power loss or fluctuation.
In accordance with these aims and objectives, the present invention is concerned with the provision of a delay circuit for automatically preventing the permanent closure of an electrically-operated device such as a gas solenoid valve when the power interruption or fluctuation does not exceed a predetermined time period. During the short interval when the gas valve is closed upon a momentary power interruption, the volume of gas in the main gas line upstream of the utilization points is sufficient in most instances to maintain the gas-operated equipment in operation. The device of the invention is capable of automatically reopening the valve to supply gas to the utilization points after such voltage interruptions less than predetermined durations. Therefore, it can be seen that the necessity of manually reactivating the gas equipment such as by re-lighting pilots lights, burners and the like is completely alleviated when the power interruption is within a predetermined time interval.
However, once a power interruption does occur which exceeds a predetermined time interval, a sensory indication means is provided in the present invention to warn personnel in the vicinity of the utilization points that the gas valve has been closed due to a power interruption which is greater than a predetermined interval. Thus, the personnel can take immediate action in checking the gas equipment for re-activation, if necessary, as soon as possible to insure that detrimental interruption of the operation of the equipment does not occur.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more fully apparent from the following detailed description when read in conjunction with the appending drawing in which there is shown an electrical schematic diagram of one embodiment of the delay circuit of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For convenience of illustration, the present invention is described in conjunction with electrically-operated gas solenoid valves but the use of device of the invention is not intended to be so limited. The present invention has numerous possible applications in other fields since the invention pertains to a delay circuit for either automatically preventing the permanent closure of an electrically-operated device and providing a convenient and effective warning system.
Referring now in detail to the drawing of the particular illustration, there is shown an embodiment of the circuit of the present invention. The input power of alternating current to the delay circuit is provided by a suitable source adapted to be coupled to the left side or external side of a terminal block TB 101. The "hot side" of the line input power such as from a 120 volt source shown as 120 VAC is applied to the terminal block TB 101-3 while a neutral input line is coupled to the terminal block TB 101-2. It should be noted that the 120 VAC line is generally connected through a fire control device such as a switch or circuit breaker (not shown) and/or any other type of suitable external equipment, which is activated upon a short-circuit or a fire as a circuit breaker between the input source and input connection to the instant circuit.
The other side or right side of the terminal block TB 101-2 is connected to a terminal block TB 102 at terminal 2 while the terminal block TB 101-3 is connected to the terminal block TB 102 at terminal 1. The lower side of the terminal block TB 102-1 is electrically coupled to one side of a conventional manual reset switch S 103 for reasons to be explained in detail later. Switch S 103 includes an additional contact which is connected to the lower side of the terminal block TB 102-5. The upper side of the terminal block TB-102-1 is connected to the wiper or arm C of a relay K1.
The lower side of the terminal block TB 102-2 is further coupled to one side 104b (neutral) of an electrically-operated gas solenoid valve 104 which controls the flow of gas through a main gas line (not shown) to gas-operated equipment situated downstream of the valve. In addition, this terminal in connected to side 106b, 105b (neutral) of a suitable alarm system such as horn 105 and a light source 106. The upper side of the terminal block TB 102-2 is connected to one input side 107b (neutral) of a full wave rectification bridge 107.
The upper side of the terminal block TB 102-3 is connected to the other input side 107a (120 VAC) of the rectification bridge 107 and to the normally opened contact NO of the relay K1. The lower side of the terminal block TB 102-3 is attached to the other side 104a of the solenoid valve 104. The lower side of the terminal block TB 102-4 is electrically connected to the other side 105a and 106a of the horn 105 and the light source 106. The terminal block TB 102-4 on its upper side is connected to the normally closed contact NC of the relay K1. The upper side of the terminal block TB 102-5 is connected to the upper side of the terminal block TB 102-3.
The load side of the rectification bridge 107 is connected across capacitor 108 which is coupled in parallel with the coil of the relay K1. The positive output terminal 107c of the bridge is connected to the positive side of capacitor 108 whereas the negative voltage output terminal 107d of the bridge is interconnected with the negative side of the capacitor 108.
In normal operation, there is applied a 120 VAC line voltage across terminals 2 and 3 of the terminal block TB 101. The relay K1 will be energized and the arm C of the relay K1 will be in contact with the normally opened contact NO. Thus, the 120 VAC line voltage on TB 101-3 will be able to pass through to the normally opened relay contact NO to the "hot" side 104a of the electrically-operated gas solenoid valve 104 connected to TB 102-3. Consequently, the valve 104 connected generally at the inlet of the main gas line will be opened thereby allowing gas to flow downstream of the line to gas operated equipment such as gas stoves, ovens and the like utilized in manufacturing facilities, industrial plants, food preparation facilities, restaurants and the like. These gas-operated devices are conventionally provided with gas consuming elements which control the operation thereof.
When there is a power failure, momentary fluctuation or surge, the capacitor 108 which has been previously fully charged will begin to discharge through the coil of the relay K1. However, the relay will remain energized and connection between the arm C and the normally opened contact NO will be maintained until the capacitor is completely discharged. Consequently, if sufficient power is again restored before the capacitor 108 has completely discharged, the solenoid valve 104 will be activated or opened again allowing normal operation to resume.
On the other hand, if there is a power failure, momentary fluctuation or surge which exceeds a pre-selected time interval (such as the time needed to fully discharge the capacitor), the capacitor 108 which has been previously fully charged will become completely discharged through the coil of the relay K1. The amount of time that it takes for the capacitor 108 to be completely discharged will be dependent upon the voltage-rating of the capacitor employed in the circuit. The capacitor 108 can be selected to give any desired amount of discharge time. Although not intended to be so limited, capacitor 108 may possess a substantial total discharge in approximately six seconds. However, any other capacitor providing other discharge times may be used in conjunction with the invention depending on desired results. Once the capacitor has discharged completely, the relay K1 will be de-energized and the relay contact will return to its normally closed position (NC). This will, in turn, cause disconnection of the "hot" side 104a of the solenoid valve 104 from the 120 VAC line on TB 101-3. Consequently, the solenoid valve 104 will remain closed and prevent further flow of the gas in the line to the gas utilization points.
Assuming that the power is again being applied to terminals 2 and 3 of TB 101 the reset switch S 103 must be manually depressed which will supply current from the 120 VAC line on TB 101-3 to the terminal 107a on the bridge as the initial step to restore operation of the equipment to normal operation. The output of the bridge 107 will then recharge the capacitor 108 to re-energize the relay K1. Also, the 120 VAC line on TB 101-3 will be able to be directed through the normally opened contact of the relay K1 to the terminal 104a of the solenoid valve 104. Thus, the solenoid valve 104 will be re-activated to an open position to allow gas through the gas line to the gas-operated equipment. Since the flow of gas has resumed, the equipment can be re-activated for its normal operation.
Since it is a very costly and time-consuming process to require an operator to re-light all of the ovens, stoves and the like each time there is a power failure or fluctuation, it would be undesirable to make necessary such a re-lighting process when the power loss is only due to a transient in the line voltage which lasts only a very few seconds or less. Accordingly, when the power loss in this preferred embodiment is less than approximately six seconds as determined by the capacitor 108, the relay K1 will not become de-energized, and thus, once power is restored, the 120 VAC line will be able to supply current through the normally opened contact NO of the relay K1 to re-activate the solenoid valve 104 to resume the supply of gas to the equipment. Under most circumstances the volume of gas in the line downstream of the momentarily closed valve will be sufficient to continue the operation of the equipment during such brief power interruptions.
However, when the power loss does exceed the selected limit and is then subsequently restored, the horn 105 will be activated and the light will visually indicate that a prior power interruption has occurred and that the valve 104 will not automatically re-open even when the power has resumed. Since the relay K1 will be de-energized, the 120 VAC line will pass through the normally closed contact NC of the relay K1 to supply current to the "hot" side 105a and 106a of the horn and the light. Of course, when the reset switch S 103 is depressed to re-activate the solenoid valve 104, this will de-activate the horn and light as the 120 VAC line on TB 101-3 will be switched from the normally closed contact to the normally opened contact of the relay K1 thereby removing current from the "hot" side 105a and 106a.
From the foregoing description of the delay circuit embodying the present invention, it can be seen that there is provided an improved delay circuit which automatically prevents the permanent closure of an electrically-operated device because of momentary fluctuations of input power of less than a predetermined time interval. Further, a visual and sound sensory alarm system is provided to indicate a prior power failure which exceeds a predetermined time period.
While there has been illustrated and described what is at present to be a preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, the equivalents may be substituted for elements thereof without departing from the true scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the central scope thereof. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as a best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A delay circuit includes a switching element for operatively switching between a first position and a second position. The switching element connects an input voltage to an electrically-operated device in the first position. A delay element is operatively connected to the switching element for maintaining the switching element in the first position when an input voltage interruption occurs which is less than a pre-determined time interval. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a condenser-containing, ceramic multi-layer circuit board and a semiconductor module and a computer having the said circuit board.
With recent demands for faster electronic computers, the number of logical circuits susceptible to the simultaneous switching is increasing and generation of noises due to the simultaneous switching has been so far problems. In order to reduce the noises due to the simultaneous switching, it has been proposed to insert condensers into the circuits. [Japanese Patent Application Kokai (Laid-open) No. 57-56217]. By the insertion of the condensers, the noise voltage can be reduced and if the permissible noise level can be further made equal to the conventional noise level, the rise time of signal wave form, etc. can be shortened, so that a computing speed can be made about 1.5 times as high. Furthermore, the signal wave form can be effectively improved by the insertion of the condensers.
In order to fully obtain the effect of the condenser, the condenser must be provided as near a semiconductor chip as possible. In order to provide the condenser at a higher density, the condenser must be provided in a ceramic multi-layer circuit board.
Heretofore, a multi-layer circuit board having a condenser has been disclosed, for example, in Japanese Patent Applications Kokai (Laid-open) No. 57-37818 and 62-244631. That is, Japanese Patent Application Kokai (Laid-open) No. 57-37818 proposes to provide a number of small independent condenser elements in parallel connection in the individual layers in order to reduce the thermal stress due to a difference in the thermal expansion between the condenser dielectric material and the insulating material.
Japanese Patent Application Kokai (Laid-open) No. 62244631 proposes to provide a number of condensers in the individual layers in such a structure that the condenser dielectric material is in contact with the througholes through which electrical signals are transmitted. When the condenser dielectric material is provided in contact with the throughholes, as disclosed in Japanese Patent Application Kokai (Laid-open) No. 62-244631, a large time delay takes place in the transmission of electrical signals through the resions of high dielectric constant, and the higher speed effect ascribed to the provision of the condensers cannot be fully attained.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a condenser-containing, ceramic multi-layer circuit board without impairing the electric signal transmission speed and a semiconductor module and a computer having the circuit board.
That is, the present invention provides a condenser-containing, ceramic multi-layer circuit board which comprises a plurality of layers of ceramic insulating material having circuit conductors, throughholes and condensers composed of ceramic dielectric condenser material having a higher dielectric constant than that of the ceramic insulating material and a pair of electrodes sandwiching the ceramic dielectric condenser material, the condensers being in a layer structure with openings concentric to the individual throughholes and having a larger diameter than the diameter of the throughholes with a distance between the condenser opening edges surrounding the corresponding throughholes and the throughhole peripheral edges, thereby forming clearances therebetween and the ceramic insulating material being filled in the clearances between the condenser opening edges and the corresponding throughhole peripheral edges without any contact with the ceramic dielectric condenser material and the throughholes.
The present invention further provides a semiconductor module which comprises a multilayer board, a carrier board provided on the multi-layer board and a semiconductor device provided on the carrier board, the carrier board being a condenser-containing, ceramic multi-layer circuit board which comprises a plurality of layers of ceramic insulating material having circuit conductors, throughholes and condensers composed of ceramic dielectric condenser material having a higher dielectric constant than that of the ceramic insulating material and a pair of electrodes sandwiching th ceramic dielectric condenser material, the condensers being in a layer structure with openings concentric to the corresponding throughholes and having a larger diameter than the diameter of the throughholes with a distance between the condenser opening edges surrounding the corresponding throughholes and the throughhole peripheral edges, thereby forming clearances therebetween and the ceramic insulating material being filled in the clearances between the condenser opening edges and the corresponding throughhole peripheral edges without any contact with the ceramic dielectric condenser material and the throughholes.
The present invention still further provides a computer which comprises a semiconductor module which comprises a multi-layer board, a carrier board provided on the multi-layer board and a semiconductor device provided on the carrier board, the carrier board being a condenser-containing, ceramic multi-layer circuit board which comprises a plurality of layers of ceramic insulating material having circuit conductors, throughholes and condensers composed of ceramic dielectric condenser material having a higher dielectric constant than that of the ceramic insulating material and a pair of electrodes sandwiching the ceramic dielectric condenser material, the condensers being in a layer structure with openings concentric to the corresponding throughholes and having a larger diameter than the diameter of the throughholes with a distance between the condenser opening edges surrounding the corresponding throughholes and the throughhole peripheral edges, thereby forming clearances therebetween and the ceramic insulating material being filled in the clearances between the condenser opening edges and the corresponding throughhole peripheral edges without any contact with the ceramic dielectric condenser material and the throughholes.
Increased delay of the signal transmitting through the throughholes in the structure of the conventional condenser-containing ceramic multi-layer circuit board is due to the contact of the condenser dielectric material of high dielectric constant with the throughholes. The present invention is based on such a structure that an insulating material of low dielectric constant is provided in clearances between the opening edges of the condenser dielectric material of high dielectric constant surrounding the corresponding throughholes and the corresponding throughhole peripheral edges. With this structure the influence of the condenser dielectric material having a high dielectric constant upon the time delay in the electric signal transmission through the throughholes can be reduced.
Suppose that the computing speed can be made about 1.5 times as high by inserting a condenser layer having openings concentric to the throughholes and surrounding the corresponding throughholes with a distance into the circuit, and filling the insulating material into the clearances therebetween, thereby reducing the electric noise, and that the dielectric constant of the ceramic insulating material is 5, that of the ceramic dielectric material 10,000 and the throughhole diameter 100 μm in case of forming a condenser layer having a thickness of about 50 μm in a ceramic multi-layer circuit board having a thickness of 1 mm. In order to make the signal transmission speed through the board higher than that without any con denser layer, it is necessary to suppress an increase in the time delay through the board due to the provision of the condenser layer to less than 50%. The distance between the throughhole peripheral edge and the corresponding opening edge of the condenser dielectric material surrounding the individual throughholes must be 5 μm or more.
Furthermore, when the throughholes are provided at a pitch of 500 μm, the distance between the throughhole peripheral edges and the corresponding opening edges of the condenser dielectric material surrounding the individual throughholes must be less than 200 μm. So long as the distance between the throughhole peripheral edges and the corresponding opening edges is 5 μm or more, a change in the distance has a smaller influence upon the signal transmission speed through the throughholes, and thus such a distance is preferable for the preparation of the boards. More preferably, the distance must be 50 μm or more in view of suppression of an increase in the delay time to less than 20% and a higher reliability in the preparation of the boards.
The present invention will be described in detail below, referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE INVENTION
FIG. 1A is a schematic plan view showing a condenser-containing, ceramic multi-layer circuit board according to one embodiment of the present invention.
FIG. 1B is a cross-sectional vertical view along the line 1B--1B of FIG. 1A.
FIGS. 2A, 2B, 2C and 2D show steps of preparing a condenser-containing ceramic multi-layer circuit board according to the present invention.
FIG. 3 is a diagram showing a relationship between the distance between the throughhole peripheral edge and the condenser dielectric material opening edge and the time delay.
FIG. 4A is a diagram showing a relationship between a ratio of the condenser thickness to the board thickness and a lower limit of the distance between the condenser dielectric material opening edge and the corresponding throughhole peripheral edge necessary for suppressing an increase in the time delay to less than 50%.
FIG. 4B is a schematic cross-sectional view of a condenser-containing board defining symbols used in FIG. 4A.
FIG. 5 is a schematic diagram showing a ceramic multi-layer circuit board containing a circuit and a plurality of condensers in a layer structure.
FIG. 6 is a schematic view of a semiconductor module provided with a condenser-containing ceramic multi-layer circuit board according to the present invention as a carrier board.
FIG. 7 is a schematic diagram of a condenser-containing multi-layer circuit board, where polyimide is used as an insulating material around the condenser.
DETAILED DESCRIPTION OF THE INVENTION
A condenser dielectric material can be formed in a multi-layer circuit board by a green sheet method using a green sheet of condenser dielectric material, a thick film printing method, sputtering, CVD, vapor deposition, etc.
Preparation of a condenser-containing, ceramic multi-layer circuit board by a green sheet method or a thick film printing method will be described below, referring to FIGS. 1A and 1B.
FIG. 1A is a schematic plan view showing a condenser-containing, ceramic multi-layer circuit board and FIG. 1B is its cross-sectional view along the line 1B--1B of FIG. 1A, where numeral 1 is a throughhole, 2 a condenser ceramic dielectric material in a layer structure, 3 electrode conductors, and 4 a ceramic insulating material. As shown in FIGS. 1A and 1B, openings concentric to the throughholes and having a larger diameter than that of the throughholes are provided through a relatively thin condenser dielectric material layer (condenser green sheet) to provide clearances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges. Then, the condenser green sheet is sandwiched between deformable insulating material green sheets, and pressed together with a hot press, whereby the insulating material of the insulating material green sheets is entered into the clearances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges. Then, the resulting laminate is fired, whereby such a structure that the dielectric material of low dielectric constant exists in the clearances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges can be obtained.
The condenser dielectric material of high dielectric constant for use in the present invention must have a dielectric constant of at least about 5,000 and can be sintered at a temperature of not more than 1,000° C., and includes, for example, a solid solution of perovskite structure composed of PbO, Fe 2 O 3 , WO 3 , PbTiO 3 , etc.
As already described above, a ceramic insulating material of low dielectric constant is provided in clearances between the opening edges of condenser ceramic dielectric material surrounding the corresponding throughholes with a distance and the peripheral edges of the corresponding throughholes in the present invention, whereby the influence of the condenser dielectric material having a high dielectric constant and giving a delay in the electrical signal transmission through throughholes can be reduced. The ceramic insulating material for use in the present invention includes, for example, borosilicate glass, borate glass containing SiO 2 powder and Al 2 O 3 powder, borosilicate glass containing alumina, etc., which can be sintered at a temperature of not more than 1,000° C. As the insulating material around the condenser dielectric material, organic insulating materials such as polyimide resin can be also used.
The electrode material, wiring conductor material and throughhole conductor material for use in the present multi-layer circuit board includes, include for example, Ag-Pd, Au and Ag.
With the aforementioned structure of the present condenser-containing, ceramic multi-layer circuit board, using the aforementioned materials, the signal transmission speed through the throughholes can be less impaired.
PREFERRED EMBODIMENTS OF THE INVENTION
The present invention will be described in detail below, referring to Examples, where parts and % are by weight.
EXAMPLE 1
A condenser-containing, ceramic multi-layer circuit board was prepared in the following manner.
At first, a slurry for an insulating material green sheet was prepared by mixing glass powder composed of 9 to 15% of MgO, 0 to 5% of CaO, 35 to 45% of Al 2 O 3 and 40 to 55% of B 2 O 3 in terms of the oxides, the total being 100%, and having an average particle size of 5 μm with SiO 2 powder having an average particle size of 1 μm as raw material powder in a mixing ratio of the glass powder to the SiO 2 powder of 95-40 to 5-60, and adding 20 parts of a methacrylate-based binder, 124 parts of trichloroethylene, 32 parts of tetrachloroethylene and 44 parts of n-butyl alcohol to 100 parts of the resulting raw material powder mixture, and subjecting the mixture to wet blending in a ball mill for 24 hours. Then, the resulting slurry was adjusted to an appropriate viscosity by vacuum deaeration treatment, applied to a silicone-coated polyester film to a thickness of 0.5 mm by a doctor blade, and dried. Then, the polyester film was removed therefrom to obtain an insulating material green sheet.
Likewise, a condenser dielectric material green sheet having a thickness of 50 μm was prepared from a dielectric ceramic material composed mainly of PbO, Fe 2 O 3 , WO 3 , TiO 2 and Nb 2 O 5 and having a structural formula of Pb (Fe 1/2 Nb 1/2 ) O 3 - Pb (Fe 1/3 W 2/3 ) O 3 PbTiO 3 and a dielectric constant of about 10,000.
In FIGS. 2A, 2B, 2C and 2D, steps for preparing the condenser-containing, ceramic multi-layer circuit board are shown.
As shown in FIG. 2A, the insulating material green sheet 4 composed of the glass powder and the SiO 2 powder was provided with a plurality of holes 1' having a diameter of 100 μm at a pitch of 450 mm, and then, as shown in 2B, an Ag-Pd conductor paste having a Pd content of 15 to 30% and an appropriately adjusted viscosity was filled in the holes 1' through the insulating material green sheet 4 as throughholes 1 and an electrode pattern 3 identical to the pattern of a condenser and partially with connection conductor parts from the electrode pattern 3 to the throughholes 1 was printed on the insulating material green sheet 4 with an Ag-Pd conductor paste having a Pd content of 15 to 30%.
Then, as shown in FIG. 2C, the condenser dielectric material green sheet 2 was provided with the same number of opening 13 concentric to the holes 1' and having a diameter of 300 μm, and placed on the insulating material green sheet 4 with the Ag-Pd conductor paste-filled throughholes 1 and the Ag-Pd conductor paste-printed electrode pattern. Then, another insulating material green sheet with the throughholes and the electrode pattern prepared in the same manner as above was placed on the condenser dielectric material green sheet 2 so that the condenser dielectric material green sheet 2 can be sandwiched between the electrode patterns 3 on the upper and lower insulating material green sheets 4. Then, the same insulating material green sheets only with the Ag-Pd conductor paste filled throughholes were placed thereon, and the resulting laminate was pressed with a hot press under pressing conditions of 100° C. and 10 kg f/cm 2 , whereby a board shown in FIG. 2D was obtained. That is, the insulating material was entered from the insulating material green sheets into the clearances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges by the pressing. The thus prepared laminate board was heated at a temperature increase rate of less than 100° C./hr to remove the binder therefrom, then defatted at 500° C. for 3 hours and then fired at 900° to 1,000° C. at a temperature increase rate of 200° C./hr in the air.
The capacity of condenser formed in the thus prepared board was about 0.1 μF and the thickness of the condenser dielectric material layer was 40 μm. Neither cracking nor peeling was observed at all on the insulating material around the condenser. Neither warping nor deformation of the board was observed at all. According to this example, the electrical signal transmitting through the throughholes in the board had a time delay of 40% on the basis of the time delay when the condenser dielectric material is in contact with the throughholes, since there was the insulating material of low dielectric constant in clearances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges, and thus the signal transmission could be made 60% faster. The condenser-containing, ceramic multi-layer circuit board of this Example had a thickness of 1 mm, a distance of 80 μm between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges and a throughhole diameter of 80 μm.
EXAMPLE 2
On the electrode pattern on the dried insulating material green sheet with Ag-Pd conductor paste-filled throughholes and the Ag-Pd conductor paste-printed condenser electrode pattern prepared in Example 1 and shown in FIG. 2B, a paste of the same dielectric material as used in Example 1 was printed as shown in FIG. 2C to provide a condenser dielectric material layer, as shown in FIG. 2C, and another insulating material green sheet with the filled throughholes and the condenser electrode pattern was placed thereon in the same manner as in Example 1, and also a plurality of the insulating material green sheets were placed thereon and then the resulting laminate was pressed and fired in the air in the same manner as in Example 1.
The capacity of the condenser contained in the thus prepared board was about 0.2 μF and the thickness of the condenser dielectric material layer was 20 μm. Neither cracking nor peeling was observed at all on the insulating material around the condenser, and neither warping nor deformation of the board was observed at all. The distance between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges was 80 μm, and the time delay of this Example based on the time delay when the condenser dielectric material was in contact with the throughholes was 60%, and the signal transmission could be made 40% faster.
EXAMPLE 3
An insulating material green sheet was prepared from a slurry made by mixing 100 parts of LiO 2 -Al 2 O-SiO 2 -based glass powder composed of 10 to 13% of Li 2 O, 70 to 80% of SiO 2 , 5 to 15% of Al 2 O 3 , 2 to 3% of K 2 O and 1 to 2% of CaF 2 , total being 100%, in terms of oxides and having an average particle size of 5 μm with 88 parts of polyvinylbutyral having a degree of polymerization of 4,000, 124 parts of trichloroethylene, 32 parts of tetrachloroethylene and 44 parts of n-butyl alcohol in a ball mill for 24 hours in the same manner as in Example 1.
Then, the holes of the insulating material green sheet were filled with the Ag-Pd conductor paste an the condenser electrode pattern was printed with the Ag-Pd conductor paste in the same manner as in Example 1.
Then, the condenser dielectric material green sheet having openings concentric to the corresponding throughholes and having a larger diameter than that of the corresponding throughholes, prepared in the same manner as in Example 1, was sandwiched between the insulating material green sheets prepared above and a plurality of the insulating material green sheets only with the throughholes were placed thereon, and the resulting laminate was pressed and fired at 900° to 950° C. in the air.
The capacity of the condenser formed in the resulting board was about 0.1 μF and the thickness of the condenser dielectric material layer was 40 μm. Neither cracking nor peeling was observed at all on the insulating material around the condenser dielectric material. The distance between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges was 80 μm. The time delay of this Example was 40% on the basis of the time delay when the condenser dielectric material was in contact with the throughholes, and thus the signal transmission could be made 60% faster.
EXAMPLE 4
Filling of the throughholes and printing of condenser electrode pattern of the insulating material green sheet prepared in Example 3 were carried out with the same Ag-Pd conductor paste and printing of the condenser pattern was carried out with the same condenser dielectric material as used in Example 2, and then further lamination and pressing were carried out in the same manner as in Example 2, and then the resulting laminate was fired at 900° to 950° C. in the air.
The capacity of the condenser formed in the resulting board was about 0.2 μF and the thickness of the condenser dielectric material layer was 20 μm. Neither cracking nor peeling was observed at all on the insulating material around the condenser dielectric material. The distance between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges was 80 μm and the time delay of this Example was 60% on the basis of the time delay when the condenser dielectric material was in contact with the throughholes. Thus, the signal transmission could be made 40% faster.
EXAMPLE 5
A condenser-containing, ceramic multi-layer circuit boards were prepared in the same manner as in Examples 1 to 4 except that the filling of throughholes and printing of condenser electrode patterns and connection parts were carried out with a gold paste in place of the Ag-Pd conductor paste. Neither cracking nor peeling was observed at all on the insulating material around the condenser dielectric material. By use of the gold paste, highly reliable, condenser-containing, ceramic multi-layer circuit board could be obtained against migration, etc. The time delay of this Example was 40 to 60% on the basis of the time delay when the condenser dielectric material was in contact with the throughholes. That is, the signal transmission could be made 60 to 40% faster.
EXAMPLE 6
Condenser-containing, ceramic multi-layer circuit boards with varied distances between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges were prepared by the green sheet method in the same manner as in Example 1 and by the thick film printing method in the same manner as in Example 2. The thickness "d", as defined in FIG. 4B, of the condenser dielectric material layer was about 50 μm for the board prepared by the green sheet method and about 20 μm for the board prepared by the thick film printing method. The time delay of electrical signal transmitting through the throughholes increased if the condenser dielectric material approached the throughholes. FIG. 3 shows a relationship between the distance W (μm on the abscissa) between the condenser dielectric material opening edges and the throughhole peripheral edges and the time delay (% on the ordinate) of the condenser-containing boards on the basis of the time delay when the condenser dielectric material was in contact with the throughholes (100%).
EXAMPLE 7
Condenser-containing, ceramic multi-layer circuit boards with varied thickness of the condenser dielectric material layer were prepared in the same manner as in Examples 1 to 4.
FIG. 4A shows a relationship between a ratio of the thickness "d" of condenser dielectric material layer to the thickness "t" of the board (on the abscissa) i.e., t/d, and the necessary and minimum distance "W" between the condenser dielectric material opening edges and the corresponding throughhole peripheral edges for suppressing an increase in the time delay of transmitted signals to less than 50% on the basis of the absence of the condenser dielectric material in the board.
FIG. 4B defines the terms, "W", "d" and "t" used in FIG. 4A.
EXAMPLE 8
On a plurality of laminates of a condenser dielectric material layer prepared in the same manner as in Example 1 or 2, sandwiched between the insulating material green sheets prepared in the same manner as in Example 1, 2, 3 or 4 and provided with the filled throughholes and the printed condenser electrode patterns in the same manner as in Example 1 were placed a plurality of insulating material green sheets with the filled throughholes at different positions from those of the first insulating material green sheets and also with the wirings. The resulting laminate was pressed and fired at 900° C. to 1,000° C. in the air. The thus prepared ceramic multi-layer circuit board containing a plurality of condenser dielectric material layers and the wirings is shown in FIG. 5.
Neither cracking nor peeling was observed at all on the insulating material around the condenser dielectric material. Furthermore, neither warping nor deformation of the board was observed at all. It was possible to provide a plurality of condenser dielectric material layers in a ceramic multi-layer circuit board as in this Example. The time delay of this Example was about 30 to 40% on the basis of the delay time when the condenser dielectric material was in contact with the throughholes and thus the signal transmission could be made 70-60% faster.
EXAMPLE 9
The condenser-containing, ceramic multi-layer circuit board prepared in Example 8 and shown in FIG. 5 was applied as a carrier board for a semiconductor module as shown in FIG. 6.
FIG. 6 shows one embodiment of a semiconductor module having the present condenser-containing, ceramic multi-layer circuit board as a carrier board, where a Si chip 24 as a semiconductor device was connected to a Si chip cooling plate 18 through a low melting solder 14 at the back side, and the cooling plate 18 was connected to a nickel bellows 15, through which water 17 flows to cool the cooling plate 18. The electrodes on the surface of the Si chip 24 were connected to the upper surface of the condenser-containing, ceramic multi-layer circuit board as the carrier board 19 through solder (Pb-5% Sn) bumps, and the clearances between the Si chip 24 and the carrier board 19 were filled with resin 10. The parts on the lower surface of the carrier board 19, as electrically connected to the soldered parts on the upper surface of the carrier board 19 through the throughholes 1, were further connected to a multi-layer board 21 through solder bumps 22 (Pb-60% Sn), that is, to the desired printed circuits in the multi-layer board 21. In the structure of FIG. 6, the Si chip 24 and the carrier substrate 19, as connected to each other through the solder bumps 23, with the resin 10 filled in the clearances between the solder bumps 23 constitute a semiconductor package structure.
The resin 10 was an epoxy resin containing quartz power, etc. and having a coefficient of thermal expansion on the same level as that of the solder bumps 23. The multi-layer board 21 was composed of Al 2 O 3 . The solder bumps 22 were different in composition from the solder bumps 23 and had a lower melting point to facilitate resoldering.
The resin 10 had a coefficient of thermal expansion substantially on the same level as that of the solder bumps 23 to make stress dispersion and the carrier substrate 19 had a coefficient of thermal expansion substantially on the same level as that of the multi-layer board 21 to prevent a thermal stress between the carrier board 19 and the multi-layer board 21. That is, a thermal stress due to a difference in the coefficient of thermal expansion between the semiconductor chip 24 and the multi-layer board was prevented thereby. At the same time, the semiconductor chip 24 and the multi-layer board could be readily resoldered together with the carrier board 19, and the semiconductor chip or the semiconductor module could be readily and economically inspected or maintained.
In this Example, the multi-layer board 21 was composed of 30 layers with a tungsten conductor, where the tungsten on the surface conductor layer was plated with nickel and coated with gold. On the surface of semiconductor chip 24, a SiO 2 film was formed on the Al film, whereas, on the electrode parts, the SiO 2 film was removed and a Cr film having a thickness of 0.7 μm, a Cu film having a thickness of 3 μm and an Au film having a thickness of 0.1 μm were formed with Cr-CuAu instead.
The Si chip surface could be directly or indirectly cooled with a liquid. Beside the structure shown in FIG. 6, an cooling or liquid cooling could be carried out through a metal, ceramics, etc. as a heat transmission medium.
With this structure, the reliability of connecting the semiconductor device to the multi-layer board could be enhanced. Furthermore, the condenser layers could be provided at positions as near the semiconductor device as possible and thus the simultaneous switching noise could be effectively reduced.
With the condenser contained in the ceramic multi-layer circuit board, the computing speed of a large scale electronic computer could be made 50% faster.
EXAMPLE 10
FIG. 7 schematically shows an application of polyimide resin as an insulating material around the condenser dielectric material layer.
In case of the green sheet method, the insulating material green sheet 4 prepared in the same manner as in Example 1 or Example 3 was provided with holes for the throughholes, which were filled with the same conductor paste as used in Example 1 and a condenser electrode pattern 3 was printed on the upper surface of green sheet 4 with an Ag-Pd conductor paste as shown in FIG. 7. Then, a condenser dielectric material green sheet 2 prepared in the same manner as in Example 1 was printed with the electrode pattern 3' on the upper surface.
Then, the insulating material green sheet 4 with the filled throughholes and the condenser electrode pattern, the condenser dielectric material green sheet 2 with the electrode pattern on the upper surface as a top layer, and a plurality of insulating material green sheets 4 only with the filled throughholes were laid upon each other and the resulting laminate was pressed and fired in the same manner as in Example 1. Polyimide resin 11 was applied to the surface of the thus prepared board on the condenser dielectric material green sheet side so as to fully coat the condenser dielectric material layer as a top layer and fill the openings of the condenser dielectric material layer. Then, the polyimide resin in the regions 12 corresponding to the throughholes in the openings of the condenser dielectric material layers by etching and throughholes of Cu conductor was formed in the regions 12 corresponding to the throughholes in the openings by electroless plating.
In case of the thick film plating, a condenser electrode pattern was printed on an insulating material green sheet, and then a condenser dielectric material layer was printed thereon. After formation, pressing and firing of laminate, formation of polyimide resin insulating film and throughholes of Cu conductor were carried out in the same manner as in the case of the green sheet method.
It was possible to use an organic polymer such as polyimide resin as an insulating material on the ceramic multi-layer circuit board as in this Example. Since there was the organic polymer having a lower dielectric constant than that of the ceramic insulating material around the throughholes in the condenser dielectric material layer, the influence of the condenser dielectric material upon the signal transmission speed could be much more reduced.
The delay time of this Example was about 50% on the basis of the delay time when the condenser dielectric material was in contact with the throughholes, and thus the signal transmission could be made about 50% faster.
According to the present invention, a condenser-containing, ceramic multi-layer circuit board without impairing the signal transmission speed can be obtained, and when the present condenser-containing, ceramic multi-layer circuit board is applied to a board for a large-scale electronic computer, etc., the condenser can reduce the electric noise and thus the computing speed can be made faster than the conventional speed. That is, the computing can be made faster than the conventional one as a total computer performance. | A condenser-containing, ceramic multi-layer circuit board which comprises a plurality of layers of ceramic insulating material having circuit conductors, throughholes and condensers composed of ceramic dielectric condenser material having a higher dielectric constant than that of the ceramic insulating material and a pair of electrodes sandwiching the ceramic dielectric condenser material, the condensers being in a layer structure with openings concentric to the individual throughholes and having a larger diameter than the diameter of the throughholes with a distance between the condenser opening edges surrounding the corresponding throughholes and the throughhole peripheral edges, thereby forming clearances therebetween and the ceramic insulating material being filled in the clearances between the condenser opening edges and the corresponding throughhole peripheral edges without any contact with the ceramic dielectric condenser material and the throughholes can reduce electric noises owing to the presence of the condenser without impairing the signal transmission speed, when applied to a board for a large-scale electronic computer, thereby making the computing speed faster than the conventional one. | 7 |
BACKGROUND
[0001] The present disclosure is directed generally to resins and, in particular, to aminoplast resins and their use as binders.
[0002] Among other aminoplast resins, melamine-formaldehyde resins find wide industrial application. Owing to their characteristic tensile strength and water repellence, their use is noted as binders for cellulosic, fiberglass, and polymeric materials as well as composite blends thereof. Resins without formaldehyde used for substitution of phenolic or aminoplast resins are desired due to regulatory and health concerns. In response, the industry has attempted to put forward aminoplast resins matching the functional benefits of formaldehyde-containing resins.
[0003] There exists a continuing need for thermosetting compositions without formaldehyde which perform in many applications like melamine-formaldehyde resins and exhibit for example, tensile strength compared to conventional resins.
SUMMARY OF THE INVENTION
[0004] According to one aspect, the invention encompasses a resin composition without formaldehyde comprising the reaction product of:
a—melamine, b—at least one aldehyde of formula (1),
R—CHO (1)
in which R represents a dialkoxymethyl group, a 1,3-dioxolan-2-yl group, optionally substituted on the vertex 4 and/or 5 by one or more alkyl groups or a 1,3-dioxan-2-yl group optionally substituted on the vertices 4,5 and/or 6 by one or more alkyl groups. c—a cross linking agent, wherein the cross linking agent is glyoxylic acid, and d—at least one polyol having 2 or more than 2 hydroxyl groups.
[0010] According to another aspect, the present invention encompasses a binder comprising the aforementioned resin composition.
[0011] In still another aspect, the present invention encompasses both a method for treating a substrate with a binder disclosed herein and a treated substrate so formed.
[0012] In some instances, the resin compositions of the present invention may provide increased tensile strength, rigidity and/or water repellence to substrates to which they are applied, thereby indicating their possible potential as binders for various materials.
[0013] These and other aspects of the invention will become apparent upon review of the following specification in conjunction with the examples.
DETAILED DESCRIPTION
[0014] In one aspect, the present invention is directed to a resin composition, without formaldehyde, comprising the reaction product of:
a—melamine, b—at least one aldehyde of formula (1),
R—CHO (1)
in which R represents a dialkoxymethyl group, a 1,3-dioxolan-2-yl group optionally substituted on the vertex 4 and/or 5 by one or more alkyl groups or a 1,3-dioxan-2-yl group optionally substituted on the vertices 4,5 and/or 6 by one or more alkyl groups. c—a cross linking agent, wherein the cross linking agent is glyoxylic acid, and d—at least one polyol having 2 or more than 2 hydroxyl groups.
[0020] The expression alkoxy represents, for example, a methoxy, ethoxy, n-propoxy, 1-methylethoxy, n-butoxy, or 2-methylpropoxy radical. As an example, the alkoxy within the dialkoxymethyl group is a methoxy radical.
[0021] The expression alkyl represents, for example, a methyl, ethyl, n-propyl, 1-methyl ethyl, n-butyl, 2-methyl propyl radical.
[0022] The aldehyde of formula (1) can be chosen from dimethoxyacetaldehyde, diethoxyacetaldehyde, dibutoxyacetaldehyde, formyl-2 dioxolan-1,3 or dimethyl-5,5 formyl-2 dioxan-1,3 and mixtures thereof. As an example, the aldehyde of formula (1) is dimethoxyacetaldehyde.
[0023] Suitable polyols for the present invention include, but are not limited to, dialkylene glycol, polyalkylene glycol, glycerin, alkoxylated glycerin, polyvinyl alcohol, dextrose (and dextrose oligomers and derivatives), maltose, maltodextrins, glucose, starch, starch derivatives such as starch hydrolysis products, polyglycidol, polysaccharides (and derivatives) and their mixtures. As an example, diethyleneglycol, dipropyleneglycol, tripropoxylated glycerin, polyvinyl alcohol, dextrose, maltose, maltodextrins, glucose and their mixtures are used. As an example, the polyol is dextrose or a mixture of D-glucose, maltose and maltodextrins, i.e. corn syrup.
[0024] In one aspect, the reaction product comprises a molar ratio of about 1 to about 6 molar equivalents of aldehyde of formula (1) to melamine. In another aspect, the reaction product comprises a molar ratio of about 2 to about 4 molar equivalents of aldehyde of formula (1) to melamine. In one aspect, the reaction product comprises a molar ratio of about 0.01 to about 0.5 molar equivalent of glyoxylic acid to melamine. In another aspect, the reaction product comprises a molar ratio of about 0.05 to about 0.2 molar equivalent of glyoxylic acid to melamine. In a further aspect, the reaction product comprises a molar ratio of about 0.06 to about 0.1 molar equivalent of glyoxylic acid to melamine. Furthermore, the reaction product, in one aspect, comprises a molar ratio of about 0.05 to about 0.5 molar equivalent of polyol to melamine. In another aspect, the reaction product comprises a molar ratio of about 0.1 to about 0.3 molar equivalent of polyol to melamine.
[0025] According to another aspect, the invention provides a process for the preparation resins of the invention characterized by the condensation under agitation of melamine and of at least one aldehyde of formula (1) in aqueous solution, with an alkaline catalyst, at a basic pH between about 8 and about 10 and at a temperature between about 20 and about 100° C. Glyoxylic acid and at least one polyol then are added, while operating with a pH between about 4.5 and about 6, at a temperature between about 20 and about 100° C. and for a time period of about 0.5 to about 12 hours.
[0026] During the first step, melamine is reacted with at least one aldehyde of formula (1) at molar ratios melamine/aldehyde of formula (1) of about 1/1 to about 1/6. In one aspect, the molar ratio of melamine to aldehyde is about 1/2 to 1/4. The reaction is made at a pH between about 8 and about 10. In one aspect the reaction is made at a pH between about 9 and about 9.5. The condensation is realized at a temperature between about 20 and about 100° C. In one aspect, the condensation is realized at a temperature of between about 40 and about 60° C. Exemplary alkaline catalysts for use with the process include sodium or potassium hydroxide. The time period depends on the temperature and on the pH and is, for example, about 2 hours for a temperature of about 50-55° C. and a pH of about 9-9.5.
[0027] Melamine is a commercial product, commercialized for example by DSM company in the form of powder.
[0028] Aldehydes of formula (1) are commercial products or can be obtained easily by example under the process described in the patent application EP-A-249,530. For example, a commercially available aldehyde that can be used in the process of the present invention is dimethoxyacetaldehyde commercialized in a 60% aqueous solution and sold under the trademark Highlink® DM by Clariant (France).
[0029] During the second step of the process, in one aspect, the precondensate obtained previously is reacted with glyoxylic acid and at least a polyol at a molar ratio of melamine/glyoxylic acid of about 1/0.01 to about 1/0.5. In another aspect, the molar ratio of melamine/glyoxylic acid is about 1/0.05 to about 1/0.2. In still another aspect, the molar ratio of melamine/glyoxylic acid is about 1/0.06 to about 1/0.1 In still a further aspect, the molar ratio of melamine/polyol is about 1/0.05 to about 1/0.5. In still another aspect, the molar ratio of melamine/polyol is about 1/0.1 to about 1/0.3. In one aspect, the pH is between about 4.5 and about 6. In a further aspect, the pH is between about 5 and about 6. In another aspect, the reaction is done at temperatures between about 20 and about 100° C. In still another aspect, the reaction is done at temperatures between about 40 and about 60° C. In one aspect, the reaction is done for a time period between about 0.5 and about 12 hours.
[0030] Glyoxylic acid used in the present invention is preferably in the form of an aqueous solution. In one aspect, industrial solutions having a glyoxylic acid content of 40 to 50% by weight are used. In another aspect, industrial solutions having a glyoxylic acid content of 40 to 50% by weight are used.
[0031] Resins in aqueous solution then are obtained which can, if desired, be diluted to obtain about 40 to about 80% of solid active. In one aspect, the resin can be between about 50 to about 60% of solid active in aqueous solution.
[0032] Although not wishing to be bound by theory, it is believed that using glyoxylic acid as a cross-linking agent provides superior cross-linking of the melamine resin relative to prior art cross linking agents. This cross linking is believed to provide enhanced functional characteristics upon the substrates to which they are applied. Such functional characteristic include, for example, increased tensile strength, rigidity and/or water repellence, comparable to the values achieved with formaldehyde resins.
[0033] The resins of the present invention are illustrated below in the Examples. Also, the resins of the present invention may improve tensile strength of cellulose substrates treated therewith.
[0034] Accordingly, in a further aspect, the present invention is directed to the use of these resins as binders for non-woven substrates such as, for example, fiberglass, nylon and polyester fibers used in building materials, air filters, or abrasive pads as well as for cellulose substrates such as, for example, automotive filters.
[0035] The resin application to the substrate to be treated is normally realized with a suitable catalyst. Suitable catalysts include, but are not limited to, hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid, methanesulfonic acid, aluminum salts such as aluminum chloride, aluminum hydroxychloride, magnesium chloride, zirconium sulfate, zinc chloride and their mixtures.
[0036] The catalyst generally is added in an amount of about 0.1% to about 15%, based on the weight (dry basis) of the reaction product. In one aspect, the catalyst is added in an amount of about 1% to about 10% based on the weight (dry basis) of the reaction.
[0037] The present invention also encompasses a process for binding a substrate by applying the resin composition disclosed herein to a substrate and then the curing the resin composition to the substrate.
[0038] Both the application and curing step can be accomplished by any method commonly employed within the art and are within the purview of one with ordinary skill. For example, the curing step is accomplished by heating the resin composition and substrate. The quantity of resin composition applied is application specific and is, consequently, accomplished by an artisan of ordinary skill without undue experimentation.
[0039] The following are illustrative, non-limiting examples of the present invention.
EXAMPLE 1
[0040] 170 g of melamine (1.35 mole) were mixed at ambient temperature with 629 g. of 60% aqueous dimethoxyacetaldehyde solution (3.6 moles) and a quantity of 8.7 g of sodium hydroxide at 20%. The temperature was raised to 50-55° C. and the batch then was heated under agitation for 2 hours at 50-55° C. while the pH was maintained at a value close to 9-9.5 (An adjustment in pH, if necessary, could be made with as much sodium hydroxide at 20% as necessary). After 2 hours of reaction, 13 g of a 50% aqueous glyoxylic acid solution (0.09 mole) and 50 g. of dextrose (0.3 mole; supplier Acros) were added and the mixture was heated under agitation at a temperature of about 55-60° C. for 1 hour and cooled. Then 127.2 g. of water was added to the mixture.
[0041] A yellow viscous liquid was obtained having a content in active solids of approximately 60% and a Brookfield viscosity of 136 mPa-s measured after 24 hours.
[0042] This resin presented a content of free glyoxylic acid of 0.06% (analysis by HPLC after passage on exchanging cartridge of anions then by using a REZEX™ column (OOH-0138-KO; 300*7.8 mm)) and sulfuric acid 0.05 N as eluant with a flow of 0.5 mL/min and an UV detection at 210 nm.).
EXAMPLE 2
[0043] The resin was prepared as in the Example 1 but using 0.22 mole of glyoxylic acid for 1.35 mole of melamine.
[0044] A yellow viscous liquid was obtained with a content of active solids of approximately 60% after dilution with 108.8 g of water, and a Brookfield viscosity of 540 mpa-s measured after 24 hours.
EXAMPLE 3
[0045] The resin is prepared as in the Example 1 but using 0.54 mole of glyoxylic acid for 1.35 mole of melamine.
[0046] A yellow viscous liquid was obtained with a content of active solids of approximately 60% after dilution with 59.5 g of water, and a Brookfield viscosity of 840 mPa-s measured after 24 hours.
COMPARATIVE EXAMPLE 1
[0047] 170 g of melamine (1.35 mole) were mixed at ambient temperature with 629 g of an aqueous solution of 60% of dimethoxyacetaldehyde (3.6 moles) and a quantity of 8.7 g. of sodium hydroxide at 20%. Then this mixture was heated under agitation during 2 hours at 50-55° C. while maintaining a pH at or near a range of 9-9.5.
[0048] After 2 hours reaction, 50 g. of dextrose (0.3 mole; supplier Acros) was added and the mixture then was heated under agitation at a temperature of about 55 to 60° C. during one hour and then cooled.
[0049] After dilution with 139.8 g of water, a yellow fluid liquid was obtained, having a content of active solids of approximately 60% and with a Brookfield viscosity of 126 mpa-s measured after 24 hours.
APPLICATION EXAMPLES
[0050] The resin prepared in the Example 1 was evaluated as binder on a filter paper alone or with a catalyst and compared with a resin without glyoxylic acid (comparative example 1, exemplified as C in Table 1).
[0051] Test specimens of filter paper (120*15 mm; 60g/m 2 ) were impregnated with a roller in resins baths diluted at 60 g/l as to obtain an impregnation of 6 g/m 2 and then polymerized at 170° C. for 2 min., and left 3 days in an air conditioned room at 25° C. and 65% of relative humidity.
[0052] Tensile strength and breaking length then were measured with a dynanometer ZWICK (100 mm/mn) at ambient temperature.
[0053] The results obtained are presented in the Table 1 below:
TABLE 1 Witness A B C Glyoxylic acid (%) 1.3 1.3 MgCl2 (% added) 3 breaking force (N) 26.2 30.8 33.5 27.5 breaking length (km) 2.6 2.9 3.2 2.7
[0054] The above results show significant improvement of the tensile strength for cellulose paper treated with resins of the present invention compared to the comparative example C of Table 1.
[0055] It will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to the disclosed embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | Resin compositions, methods of forming such resin compositions, methods of using such resin compositions and substrates treated with such resin compositions are disclosed. One of such resin compositions contains no formaldehyde and is useful as a binder. Such resin composition comprises the reaction product of: a—melamine, b—at least one aldehyde of formula (1) as defined in the specification, c—a cross linking agent, wherein the cross linking agent is glyoxylic acid, and d—at least one polyol having 2 or more than 2 hydroxyl groups. The resin composition of the present invention can provide performance characteristics to which they are applied. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the invalid walker art.
2. Description of the Prior Art
There are a variety of invalid walkers that are well known to those of ordinary skill in the art. The inventor of the device described herein holds a number of patents directed towards invalid structures such as walkers.
Over the years there has been a long felt need for walkers with additional strength and stability. An invalid walker must be strong and stable because an invalid must rely upon it as his sole source of support. In addition to strength and stability, the structure must also be light in weight and relatively inexpensive.
Invalid walkers with bracing are fairly well known. As a matter of fact, it is not uncommon to have at least one brace interconnecting each of the front and rear legs in addition to the primary attachment structure, which is typically the handle section.
Several walkers having additional braces have been manufactured by Edco, Inc., 125 South Street, Passaic, N.J. 07055. One walker is known as the Hemi-Ambulator, Catalog item No. 2123-1903 which includes a pair of front legs connected together by a continuous U-shaped member and a U-shaped bracket having downwardly turned tips which serve as additional bracing above and beyond that normally provided by the handle section of the walker. A walker of similar construction is identified in the Edco, Inc. catalogs as Item No. 2123-1931. Edco, Inc. also sells a walker, catalog Item No. 1707, having a similar base bracing structure, but including discontinuous front legs. That walker is referred to in the literature as the Dollar Stretcher Walker. A variety of folding walkers are also available from Edco. One such folding walker is Catalog Item No. 2123-1906 and another is known as the Edcomatic Folding Walker, Models No. 2123-1916 and 1917. Due to their folding nature, it is possible to effectively brace the side legs, but it is difficult, if not impossible, to connect the two front legs by an additional brace. Edco, Inc., also produces a line of economy type walkers having a substantially continuous U-shaped bracing structure which extends across the front legs as well as between the front legs and the back legs. These economy walkers known as Models No. 2123-1801, 2123-1721 and 2123-1701 all include substantially continuous U-shaped additional bracing in which the intermediate section between the front legs may also be employed for support purposes. Of note also is the delux model No. 2123-1901 which includes a U-shaped downwardly turned bottom bracing structure.
Similar to the Edco Model No. 2123-1931 is the Sci-O-tech Deluxe Adjustable "U" Line Adult Walker, catalog No. 86,002. It includes a U-shaped pair of front legs, a continuously U-shaped pair of rear legs and another U-shaped member which provides additional bracing for the front and back legs and across the two front legs.
One advantage of the present invention is that the additional bracing may include a pair of grips located below the two normal top grips so as to assist an invalid in assuming the standing position from a sitting position. There are some walkers known to those of ordinary skill in the art which include an additional hand grip however, the additional grip is usually found at a different location on the structure. Such walkers are used, for example, in assisting invalids when they go up and down stairs. Typical of such walkers is the Edco Multipurpose Stair Walker, Catalog No. 1911. The Edco Multipurpose Stair Walker includes a pair of handles extending from the rear legs of the walker in such a manner that an invalid can place more weight on the rear legs when negotiating a stairway.
In addition to the basic walker structure, it is also known to add certain features to make the walkers more adaptable to the surroundings in which they are used. For example, it is not uncommon to include adjustable feet portions on the legs of the walker so that they can be adjusted upwardly or downwardly.
SUMMARY OF THE INVENTION
Briefly described, the invention comprises an improved invalid walker having additional bracing between the front and rear legs so as to increase the strength of the structure. The frame of the walker includes a pair of front legs connected together in a generally U-shaped fashion. The rear legs of the walker are also connected together in a generally continuous U-shaped fashion and attached at the intermediate section thereof to the intermediate section of the U-shaped front leg portion. Each front and rear leg is further connected together by two braces. The braces are part of an overall substantially structurally continuous circular member which is attached at at least one point to the rear legs and at at least two distinct points to each of said front legs. The circular member includes an upper and lower part each in turn having a generally U-shaped structure and being attached to the leg in such a fashion that the tips of the upper and lower portions almost abutt each other. The tips are then joined together by an intermediate tubing section found inside of the hollow tips. The intermediate tubing section is riveted to the rear legs of the walker through the tips of both the upper and lower sections. The legs of the walker are splayed so as to provide additional stability.
These and other featues of the invention will be more fully appreciated with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear perspective view of the invalid walker apparatus according to the preferred embodiment thereof.
FIG. 2 is a front perspective view of the invalid walker apparatus illustrated in FIG. 1.
FIG. 3 is a side elevational view of the invalid walker apparatus illustrated in FIG. 1.
FIG. 4 is a partial cross-sectional view of the invalid walker apparatus illustrated in FIG. 3, as seen from perspective 4--4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
During the course of this description like numbers will be used to indicate like elements according to the different view of the invention.
The invalid walker 10 essentially comprises a U-shaped front leg structure 12, a U-shaped, bent rear leg structure 14, and a structurally endless circular bracing member 16 interconnecting the front leg structure 12 with the rear leg structure 14. The U-shaped front leg structure 12 includes a pair of front leg members 18 interconnected by an intermediate section 20. Front legs 18 and intermediate section 20 are part of a continuous U-shaped piece of aluminum tubing. The front leg members 18 are terminated in a foot section 22 which includes a rubberized foot pad 24, a sleeve 26 which telescopes over the leg member 18 and a shock absorbing collar 28 which serves to minimize vibration. Telescoping sleeve 26 includes a plurality of locking apertures 30 and at least one spring-loaded locking pin 32. By depressing the locking pin 32 and relocating it in any one of the locking holes 30 it is possible to adjust the effective height of any one of the leg members 18.
The U-shaped rear structure 14 includes a pair of rear legs 34, a substantially horizontal handle section 36, and an intermediate section 38. Rear legs 34, handle section 36 and intermediate section 38 are continuously connected together from one side to the other so as to form a bent U-shaped structure. Each rear leg member 34 is terminated by an adjustable foot section 22 similar to those employed on the front legs 18. A rubberized grip 74 surrounds the handle section 36. Grip 74 is relatively substantial and intended to take a great deal of wear. The intermediate section 38 of the rear structure 14 is connected by a pair of rivets 40 to the intermediate section 20 of the front leg structure 12. The rivets 40 pass through a plastic-like washer 42 at the interface between the two intermediate sections 20 and 38. Washers 42 serve to eliminate squeek, vibration, and abrasion.
The endless circular bracing element 16 includes a first upper U-shaped brace member 44 and a second, lower U-shaped brace member 46. The upper U-shaped brace member 44 includes an intermediate section 48, a pair of brace side members 50, and a downwardly turned end section 52 attached to rear leg 34. A second handgrip 54 is attached to brace member 50. The purpose of the additional grip 54 is to assist an invalid in changing from the sitting position to the walking position. It has been found that it is easier for an invalid to start standing up by initially placing his weight upon brace grips 54. As the invalid continues to pull and push himself upward, he will move his hands from the lower grips 54 to the upper handle grips 74. The brace grips 54 are temporary in nature and therefore not as substantial and durable as the standard handle grips 74. The end section 52 of the upper brace structure 44 is attached to rear leg 34 by means of a rivet 56. A more complete understanding of this method of attachment may be had by referring to FIG. 4, as will be discussed below. The upper brace element 44 is also connected to the front legs 18 by a similar pair of rivets 58. Rivets 58 are attached to the upper brace structure 44 where the side brace member 50 meets the intermediate section brace member 48. End members 52, brace members 50, and intermediate section 48 are formed from a continuous U-shaped piece of aluminum tubing.
In a similar manner the lower brace structure 46 includes intermediate section 60, brace members 62 and upwardly turned ends 64. Lower end member 64 is attached to rear leg 34 by a rivet 66 and in the same manner that upper member 52 is attached to rear leg 34 by rivet 56. The lower structure 46 is attached to the front legs 18 by means of another distinct set of rivets 68 in the same manner that the upper brace structure 44 is attached to the front legs 18 by rivets 58. Rivets 68 are located at the junction between the intermediate section 60 and the side brace members 62. Intermediate section 60, the two side brace members 62 and the two upwardly turned end members 64 are formed from a continuous piece of aluminum tubing.
FIG. 4 illustrates in greater detail the way in which the upper and lower brace structures 46 form a substantially continuous circular element 16. The partial cross-sectional view of FIG. 4 describes the manner in which an interior tubular element 70 telescopes inside of the hollow downwardly facing end member 52 of the upper brace structure 44 and into the upwardly turned end member 64 of the lower brace structure 46. Rivet 56 passes through end member 52, reinforcing tubular element 70 and rear leg 34. In a similar manner, rivet 66 passes through the upwardly turned end member 64, tubular element 70 and rear leg 34. Accordingly, upper brace member 44 is structurally continuous with lower brace member 46 because it is rigidly connected thereto through rigid tubular intermediate reinforcing member 70 and rivets 56 and 66. Only a very small external gap 72 exists between end elements 52 and 64. Gap 72 is approximately 1/16" wide and has been slightly exagerated in FIGS. 1 through 4 for illustrative purposes only.
It is apparent from the foregoing that the endless circular brace structure 16 is attached at four distinct points to the front legs 18 of the walker 10. Those points are at the locations of the two upper rivets 58 and the two lower rivets 68. The continuous structure 16 is likewise attached at four points to the rear legs 34. Those four points of course correspond to the pair of upper rivets 56 and the pair of lower rivets 66. The essentially continuous nature of the circular bracing section 16 gives the walker considerably increased strength and rigidity. The increased strength and rigidity is due at least in part to the three dimensional nature of the continuous brace structure 16 and the manner in which it is attached to both the front legs 18 and the rear legs 34. In the context of this invention, element 50 can be considered a first brace and element 62 can be considered a second brace. While it is not unusual to have at least one brace in addition to a handle section in the invalid walker, the use of additional bracing similar to that described herein is believed to be otherwise unknown.
A pair of plastic-like vibration absorbing washers 42 are located between the intermediate sections 20 and 38 of the front secton 12 and the rear section 14. Washers 42 serve to eliminate the creaking that may be associated with the relative movement of intermediate section 20 with respect to intermediate section 38. Similar vibration absorbing washers are located on rivets 58 and 68 at the interface between the continuous member 16 and the front legs 18. It may also be desirable to include a set of vibration absorbing washers over rear rivets 56 and 66.
The stability of the walker 10 is due in large part to the outward flaring of the legs so as to create a wider base. As seen in FIG. 2 the rear legs 34 are kicked backwardly to a greater degree than is normal in these structures. In addition, the front legs are kicked forwardly and the side legs are kicked sidewardly in such a fashion as to increase the size and stability of the base. This feature can be understood by reference to the following dimensions. The distance between the handles at the top of the walker is approximately 20". The depth of the walker from the intermediate section 38 to the bend behind handles 37 is approximately 10 1/2". In contrast, the distance between the foot pads 24 on the front leg sections 22 in the uncollapsed state is approximately 24" in the front and 25" in the back. Likewise, the respective distance between the foot pads 24 in the front and in the rear is approximately 21". In the completely extended mode, the distance between the two front foot pads 24 is approximately 27 1/2" and between the rear foot pads 24 is approximately 26 1/2". The distance between a front foot pad 34 and the respective rear foot pad 24 is approximately 23" in the telescoped state. Also, in the telescoped state the walker stands approximately 39 1/2" tall. In the most collapsed state the walker stands approximately 32 1/2" tall. Therefore, there is normally 7" of travel between the most collapsed state and the most telescoped state of the walker 10. According to the preferred embodiment, there are eight locking holes 30 per leg located 1" apart so as to accommodate eight different height adjustments. However, only five locking holes 30 are shown in FIGS. 1 through 3 in order to avoid cluttering the illustration.
The walker is especially useful for tall and/or heavy individuals. It is useful for tall people because the base of the walker is exceptionally wide when the legs are fully extended. The walker is attractive to heavy individuals because of its uniquely strong bracing system.
One failure of prior art invalid walkers is that the back legs are frequently unstable. The walker of the present invention has overcome this difficulty not only through the use of a unique bracing system, but also through the use of continuous U-shaped structures which comprise the front and back legs. In many prior art walkers it was standard practice to separately weld or rivet the front legs and/or the back legs to an intermediate structure upon which the handles might be located. These rivets and weld locations can be a source of weakness. Accordingly, that particular problem has been overcome by maximizing the use of continuous pieces of tubing where possible.
In addition to exceptional strength and stability, the present invention is about as light as such a structure can be economically made. Virtually all of the larger items are formed from extruded aluminum tubing. The handles are made from a light weight yet durable plastic material. Accordingly, the ultimate product is very maneuverable even for people with severe handicaps.
While the invention has been described with reference to the preferred embodiment thereof, it will be appreciated by those of ordinary skill in the art that various modifications may be made in different parts of the apparatus without departing from the spirit and scope of the invention. | An improved invalid walker is provided with extra bracing between each front and rear leg so as to increase the strength of the structure. In addition to the handle section of the walker, there are two braces connecting each front leg to its respective rear leg so as to make three structural attachments between each front leg and the rear leg. The bracing structure is connected together in a unique circular manner. An additional set of hand grips may be placed on one set of the braces so as to help an invalid assume the standing position from the sitting position. The legs of the walker are splayed to improve stability. The walker has exceptional strength due to the additional bracing that exists between the front and the rear legs and the manner in which the bracing members are associated with each other. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application corresponds to French application 97 07117 of Jun. 9, 1997, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to PSA apparatus for the separation of a gaseous mixture comprising an adsorber and at least one output capacity.
BACKGROUND OF THE INVENTION
Mono-adsorber PSAs generally comprise a single capacity, simple or of the so-called segregation type, or two capacities, also simple or of the so-called segregation type. Examples are described particularly in U.S. Pat. No. 4,561,865 (Greene & Kellogg), U.S. Pat. No. 4,948,391 (Vacuum Optics Corp.), U.S. Pat. No. 4,892,566 (Air Sep. Corp.), U.S. Pat. No. 5,370,728 (Praxair) , U.S. Pat. No. 5,415,683 (Praxair) , U.S. Pat. No. 5,565,018 (Praxair) , EP 0 663 229 (Sumitomo Seika), EP 0 743 087 (L'Air Liquide). The solutions with a single capacity are preferable as to cost of equipment but do not permit optimization of the cycle nor volumes of gas to be stored. The solutions with capacities of the segregation type permit such optimizations but at the price of very high cost.
SUMMARY OF THE INVENTION
The present invention has for its object to provide a PSA apparatus and process for separation, permitting such optimizations at least cost.
To do this, according to one aspect of the invention, the apparatus comprises:
an adsorber having a supply inlet for a gaseous mixture and a gas outlet;
first, second and third capacities, the third capacity having an inlet and a gas outlet;
first means to establish bidirectional communication between the outlet of the adsorber and the first capacity;
second means to establish bidirectional communication between the outlet of the adsorber and the second capacity; and
third means to establish unidirectional communication from the outlet of the adsorber toward the third capacity.
According to another aspect of the invention, the process for using such an apparatus, comprises the successive steps of production, deep pressurization, elution and recompression, or:
in the production step, the gas product at the outlet of the adsorber is brought by the second means to the second capacity and by the third means to the third capacity;
during the depressurization step, gas is brought from the outlet of the adsorber by the first means to the first capacity; and
gas from the first and second capacities is brought sequentially by the first and second means, respectively, to the outlet of the adsorber during the steps of elution and recompression.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the present invention will become apparent from the following description of embodiments, given by way of illustration but in no way limiting, with respect to the accompanying drawings, in which:
FIG. 1 is a schematic view of a mono-adsorber PSA apparatus with three capacities according to the invention;
FIGS. 2 and 3 are examples of cycles according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, there is seen a PSA apparatus for the separation of a gaseous mixture, typically for the production of oxygen from atmospheric air, comprising an adsorber 1 and three outlet capacities 2, 3 and 4 connectable respectively to the outlet of the adsorber 1, as will be seen further on. The inlet 6 of the adsorber 1 is connected to a compression/suction unit 7 with derivation valving as disclosed in U.S. Pat. No. 4,561,865 mentioned above or with a reversible rotary machine, as described in EP 0 743 087 mentioned above.
The first capacity 2 is connected to the outlet 5 by a line 8 comprising a valve 9. The second capacity 3 is connected to the outlet 5 by a line 10 provided with a valve 11.
The third capacity 4 comprises an outlet 12, or production outlet, connectable to a user circuit, and an inlet 13 connected to the outlet 5 of the adsorber 1. In the embodiment shown in broken lines in FIG. 1, the inlet 13 is connected to the outlet 5 by a first section 14A provided with a non-return valve 15 then by a second section 14B. The apparatus moreover comprises sequentially programmable control means 20 for the first (9) and second (11) communication means and of the unit 7.
The operation of this apparatus will now be described with reference to FIG. 2 showing the phases of the PSA cycle.
As will be seen in this FIG. 2, the cycle comprises
a) a production phase in which the system 7 sends to the adsorber 1 a pressure flow of gaseous mixture to be separated, the production gas separated being brought to the second and third capacities 3 and 4 (the valve 11 being open and the valve 9 closed).
b) a step in which the preceding adsorber in the production phase a) is subjected to a first co-current depressurization, the separated gas with falling purity being brought to the first reservoir 2 (the valve 9 being open and the valve 11 closed). The pressure in this phase being less than the pressure reached at the end of the production phase, the non-return valve 15 remains closed and the depressurization gas does not reach the production capacity 4.
c) a countercurrent depressurization phase, to the low pressure of the cycle, assisted by the system 7 operating as a pump.
d) an elution phase at the low pressure of the cycle by gas of medium purity from the first capacity 2 (the valve 9 being reopened).
e) an initial co-current repressurization phase by gas of high purity from the second capacity 3 (the valve 11 being open and the valve 9 being closed), the valve 15 preventing any return of the gas in the capacity 4 to a region of lower pressure.
f) a second pressurization phase by the gaseous mixture to be separated, without removal of production gas.
Such an arrangement permits reducing the dimensions of the storage capacities whilst permitting an elution/repressurization sequence by gas separated at increasing purity.
As a modification, the line 14B could comprise, in addition to or in place of the non-return valve 15, a third electrovalve 16 controlled by control means 20 in order, during the production phase a), to send the production gas sequentially first of all to the capacity 3 alone, and ultimately to the capacity 4 alone, the valve 16 being maintained closed beyond step a).
As a modification again, as shown in phantom line 14C on FIG. 1, the downstream section 14A incorporating the nonreturn valve 15 could be connected to the outlet 5, not directly but via the second capacity 3 and its connection line 10 (the portion of line 14B is in this case omitted).
In FIG. 3, there has been shown the cycle transposed from that of FIG. 2 with this latter modification.
In the production phase a), all the production gas is sent to the small second capacity 2 and then, from there, to the third capacity 4. In phase e), upon the opening of the valve 11, the gas contained in the second capacity 3 returns to the adsorber 1 for its initial countercurrent repressurization, the one-way valve 15 preventing any return in the upstream direction of the production gas in the third capacity 4.
As a modification, the cycle shown in FIG. 3 comprises no intermediate step f) of repressurization by the single gaseous mixture to be separated, the phase a) of production, with the valve 11 open, leading directly to the initial repressurization phase e).
Although the present invention has been described in connection with particular embodiments, it is not thereby limited but on the contrary is susceptible to modifications and variations which will become apparent to a person skilled in the art. | The device comprises an adsorber (1) and three outlet capacities (2-4), first (8, 9) and second (10, 11) structure to establish bidirectional communication between the adsorber and the elution capacity (2) and the repressurization capacity (3), respectively, and third structure (14A, 15; 16) to establish unidirectional communication from the adsorber to the production capacity (4). | 1 |
RELATED APPLICATIONS
This application is a continuation-in-part of my copending application, Ser. No. 311,261, filed Dec. 1, 1972, now U.S. Pat. No. 3,872,557.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to an apparatus for conditioning fabrics and, more particularly, to apparatus for effecting superficial treatment on fabrics in a substantially continuous manner, allowing repetition of the fabric treatment without the need to dismount and reposition the treated fabric roll. In the apparatus of the present invention the direction of travel of the fabric may be reversed so that the fabric runs inversely so as to be repeatedly submitted to the superficial treatment, such reversal being effected as often as it is considered advisable until the desired effect on the fabric is obtained. The reverse operation is automatically effected in response to control means.
In order to obtain such reversible operation, the apparatus is constructed in a substantially symmetrical form with respect to a median transverse plane with regard to its operative means.
Thus, the apparatus of the present invention is especially suited for superficial grinding processes on any type of fabric, particularly in those cases in which it is desired to work with a substantially low longitudinal tension on the fabric in the course of being treated. The apparatus is particularly well adapted for use in performing the process disclosed in my copending U.S. application for Letters Patent Ser. No. 311,261, filed Dec. 1, 1972, and for producing the superficially dyed fabrics disclosed therein.
In the apparatus of the present invention, rotating grinding means are joined to respective rod-crank mechanisms such that the grinding means rotate jointly and are displaced transversely to the fabric path in a compound movement, said alternative transverse displacement being determined by the rotation speed.
Furthermore, the apparatus of the present invention has a novel device to regulate the fabric winding reels, and be virtue of such regulation the longitudinal advance tension of said fabric can be efficiently controlled during treatment. These winding devices are controlled by pneumatic braking and clutching means with adjustable friction.
These and other objects, features and advantages of the present invention will be more clearly understood through a consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of this description, reference will frequently be made to the attached drawings in which:
FIG. 1 is a side elevation view showing a schematic of the assembly of the present invention for conditioning fabrics, and in which some of the elements are broken away to show portions thereof;
FIG. 2 is a partial end elevational view of the assembly showing an end of one of the grinding means adjacent the operating motor and adjustment mechanism for its relative height;
FIG. 3 is similar to FIG. 2, but showing the opposite end of the grinding means and its rod-crank mechanism, partly in section, to show its component parts;
FIG. 4 is a cross sectional, partial side elevational view on line IV--IV of FIG. 2 showing the height adjustment mechanism of the grinding means;
FIG. 5 is a cross sectional end view showing a longitudinal section of the axle on which the fabric is wound and of the pneumatic operating mechanism therefor;
FIG. 6 is a front view of the control cabinet of the assembly;
FIG. 7 is a cross sectional side elevational view of the control cabinet shown in FIG. 6;
FIG. 8 is a cross sectional partial view of the control cabinet shown in FIG. 6;
FIG. 9 is a cross sectional end view showing the jack-wheel for reversing the direction of fabric travel in the assembly;
FIG. 10 is a partial elevational view of the jack-wheel shown in FIG. 9;
FIG. 11 is a cross sectional end view of the satellite roller of the fabric carrier roll with its toothed displacement transmission and the position fixing means;
FIG. 12 is a cross sectional elevational view showing the carrier roll with its satellite roller as shown in FIG. 11, and showing two positions of the satellite roller in solid and dot and dash; and
FIG. 13 is a cross sectional elevational view of another embodiment of carrier roll and satellite roller.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the fabric conditioning apparatus of the invention includes a support structure a above which is positioned the hood 1 of a suction system. In the illustrated example of the apparatus that is schematically represented in elevation with respect to the direction of travel of the fabric being treated, the apparatus is substantially symmetrical with respect to a median transverse plane.
On the upper portion of structure a, the guide rollers 2 are arranged transverse to the path of travel of the fabric and between grinding or abrasion cylinders 3 in the direction of the path of fabric travel. Grinding cylinders 3 constitute the fabric abrasion means. The size of the grain on the surface of cylinders 3 shown in FIG. 2 may be varied to vary the roughness of the cylinders. The grinding cylinders 3 are rotated by respective motors 4 positioned above rollers 3 by means of belts 5 arranged on pulleys 6 fixed on the axles of the cylinders 3 as shown in FIGS. 1 and 2. The direction and speed of the motors 4 may be individually controlled to control the speed and direction of the individual grinding cylinders 3 as desired. The grinding cylinders 3 may be made to rotate either opposite to or in the same direction as the direction of travel of the fabric through the assembly or individual ones of the cylinders may rotate in opposite directions.
As shown in detail in FIG. 4, the guide rollers 2 are mounted on supports 7 which are fixed to the structure a while each of the grinding cylinders 3 is mounted on a shaped support 8 which extends transversely of the apparatus and which is fixed on one end of arms 9. Arms 9 are hinged on both sides of the guide rollers 2 at the supports 7 of same. The arms 9, with the support 8 of a respective grinding cylinder 3, are angularly displaceable in an arc, the center of which substantially coincides with the axle of the corresponding guide roller 1, as shown in FIG. 4. Referring to FIGS. 1 and 2, rigid support members 10 support platforms 11 on which the motors 4 are mounted and are fixed to supports 8. Thus the spacing between the grinding cylinders 3 and platforms 10 is fixed during operation and both are simultaneously adjustable in elevation.
On both sides of the supports 8 opposite arms 9, sectors 12 are fixed. Sectors 12 are toothed and these teeth mesh with pinions 13 of complementary axles 14. One side of each axle 14 projects from structure a and carries a sprocket 15 which meshes with an endless thread 16 which is controlled by a handwheel 17. Each grinding cylinder includes the latter subassembly to vary the height of cylinders 3 individually with reference to the guide rollers 2 and with such height variations, the pressure on the fabric being treated and the contact angle of same on cylinders 3 may also be varied. The ends of the complementary axles 14 have respective gauges mounted thereon that register the angular displacement of the corresponding quadrants 18 and may be scaled at 19 to read in contact angle or pressure or both.
The ends of the axles of the grinding cylinders 3 opposite the pulley assemblies 6 each include a shaft extension 20 with an endless thread 21. Thread 21 meshes with a gear 22 as shown in FIG. 3. Each gear 22 is eccentrically pinned at 23 to the end of rod arm 24, the opposite end of which is at the same time pinned to a point 25 on support 8.
The thread 21 and the gear 22 are housed within a housing 26 mounted on bearings 27, through which the shaft 20 is journaled, such that the axle shaft 20 rotates with respect to the housing, but is connected with the housing for common axial displacement therewith in the manner pointed out by the arrows in FIG. 3 which show the axial oscillation of the axle.
As shown in FIG. 3, the gear 22 is continuously intermeshed with thread 21 to continuously rotate the gear while shaft 20 rotates. Since arm 24 is pinned to the support 8 at 25 and is eccentrically pinned to the gear 22 at 23, the shaft 20, endless thread 21, gear 22 and housing 26 will be displaced in oscillatory motion during rotation of cylinder 3 as shown by the arrows, thereby imparting the grinding cylinder 3 with a transverse movement relative to the direction of travel of the fabric simultaneously with rotation of the cylinders. Moreover, the speed of such transverse oscillations will be a function of the speed rotation of the grinding cylinders 3. The transverse oscillations of the grinding cylinders 3 are important in the prevention of streaking in the fabric.
The grinding cylinders 3 are preferably covered on the sides and top, by covers 28 from which channels 29 extend to the suction system 1.
The rollers or reels on which the fabric is wound, rollers c and c' shown in FIG. 1, are mounted at both ends of the machine. Both rollers c and c' have control devices. As shown in FIG. 5, a shaft 30, of square or similar section, is removably positioned on one side in a support 31 which preferably is open at the top and a fastening element 32 may be angularly displaced for locking or unlocking the shaft 30 with an axle 33. Axle 33 is journaled through bearings 34 and extends in housing d.
The core 35 of an annular piece 36 is fixed on axle 33 in housing d. The annular piece 36 also includes a friction surface 37 facing a similar annular piece 38 which also has a friction surface 39. The second annular piece 38 has a core 40 comprising a sleeve or bushing which is keyed to axle 33 and is axially displaceable on axle 33 by means of a thrust member 41 with bearings 42. Thus, the friction surface 37 of the annular piece 36 is fixed on axle 33 and the friction surface 39 and its annular piece 36 are axially displaceable and both rotate with the axle. A plate or sprocket 43 rotates freely on axle 33 on bearings 43' and is arranged between friction surfaces 37 and 39. Sprocket 43 is adapted to be driven by a chain 64 which passes through an opening (not shown) of casing d, but sprocket 43 may be locked against rotation as will be described in detail hereafter.
A box or cylinder e is fixed to casing d as shown in FIG. 5. Cylinder e has a connection 44 for communicating air under pressure to a pneumatic microcylinder whose piston 45, against which the return spring 46 operates, is joined to the thrust member 41 by means of a rod member 47. The air pressure conduit 48 to each of the control devices of the rollers c and c', is supplied from a control housing f, which can be located in any suitable location such as at one of the ends of the apparatus as shown in FIG. 1. The control housing f is illustrated in FIGS. 6, 7 and 8.
A conduit 49 from a source of air pressure extends into the control housing f to a two way valve for microvalve 50. The valve 50 is preferably controlled electrically through conductors 51 shown in FIG. 8.
An air conduit 52 is connected to a control valve 53 which valve may be controlled externally of the housing by knob 54 to vary the air pressure in pipe 48 and thereby, control the friction clutching and braking action in assembly d at each end of the machine. From control valve 53, the air is conducted by pipe 48 which is connected to box e of the microcylinder to operate the thrust member 41. Air from pipe 48 may also be diverted to manometer 55 on housing f for personnel monitoring. The two way valve 50 also includes an exhaust or discharge outlet 56.
One control valve 53 is preferably provided for the assembly d at each end of the machine. One valve 53 ports air to the takeup end of the machine, roller c as shown in FIG. 1, to cause the friction surfaces 37 and 39 to perform a clutching function against rotating plate 43 to drive axle 33 of the takeup roller c. The other valve also ports air to the feed or unwind end of the machine, roller c' as shown in FIG. 1, to cause the friction surfaces 37 and 39 to perform a braking function against locked plate 43 to brake axle 33 of the feed or unwind roller c' and, thereby, prevent roller c' from freewheeling. Both of these valves 53 may be controlled by a single knob 54 such that as one of the valves is being opened while the other is being closed to compensate for the inversely porportional changes in diameter of the fabric at the rollers c and c' during operation of the machine. If desired, separate control knobs 54 may be provided for each valve.
In addition to the knob 54 for operating the control valve 53, the control housing f also includes a starter button 57 and stop button 58 on its front for starting and stopping the suction device 1. The housing f also includes a button 59 for stopping the apparatus, buttons 60 and 61 for starting and reversing, respectively, the apparatus, a button 62 for starting the electrovalve 50, and a pilot light 63 for indicating operation of the apparatus. The electrical control circuitry is not illustrated, since any number of suitable circuits are available and well within the selection of one skilled in the art.
As shown in FIG. 1, the sprockets 43 of the control devices of the rollers c and c' on which the fabric is wound are connected by chains 64 to the respective mechanisms b and b', the latter of which are also connected by chains 65 to a multiple transmission mechanism t that is driven from the speed variator v of motor m as shown in FIG. 1.
Mechanisms b and b' allow reversal of the rollers c and c' on which the fabric is wound. As shown in FIGS. 9 and 10, each of the mechanisms b and b' include a ratchet mechanism including an axle 66 connected with the sprocket of chain 64 and on which a disk-shaped piece 67 is fixed. A single notch 68 is formed on the perimetral edge of piece 67. A portion 69 also projects from the disk-shaped portion having straight sides 70 to form, for example, a hexagon. Bolts 71 extend from the disk-shaped portion 67 in spaced relation to the sides 70 as shown in FIGS. 9 and 10.
A piece 72 is mounted on the end of axle 66 and rotates on bearings 73. Piece 72 has sprocket teeth 74 which are engaged by continuously drive chain 65, the latter of which is connected to the transmission mechanism t. Piece 72 has a cylindrical recess 75 surrounding the hexagonal shaped central portion 69. Freely displaceable rollers 76 are positioned at each side 70 of portion 69 between the sides 70 and the recess 75 of piece 72. These rollers 76 constitute wedging means between said pieces 67 and 72. When piece 72 is rotated in the direction of the arrow in FIG. 10 by transmission t and chain 65, the internal cylindrical perimeter of piece 72 pulls the rollers 76 to the dot and dash position shown in FIG. 10 to wedge them between the straight line surface 70 of portion 69 of piece 67 and the cylindrical perimeter of piece 72 to drivingly rotate piece 67 thereby imparting movement through chain 64 to the corresponding roller c on which the fabric is wound.
When the piece 72 is rotated in the opposite direction to the arrow in FIG. 10, the rollers 76 are pulled to the non-wedging position shown in solid in FIG. 10 and are there held by the fixed bolts 71 to prevent wedging at the other side of flat surface 70. Consequently, the piece 72 rotates freely, but does not drive portion 67 or roller c. In this condition roller c acts as a supply or unwind roller. When piece 67 is disengaged in this manner, it is immobilized by the lock pawl 77 which engages notch 68. Since piece 67 is locked, chain 64 will also be locked, locking plate 43 in assembly d shown in FIG. 5.
The lock pawl 77, one for each mechanism b and b', is connected by means of rods 78 to a control mechanism g as shown in FIG. 1, such that, when one pawl is engaged in one notch, the other is raised.
When a roller c is rotated to wind up the fabric, the corresponding roller c' at the opposite end of the machine is dragged by the fabric that unrolls from it. Since the sprocket 43 of the unwind roller c' is locked against rotation by chain 64, piece 67 and engaged pawl 77, roller c' may be selectively braked pneumatically by friction surfaces 37 and 39 to as to prevent it from freewheeling as the diameter of the fabric on the unwind roller c' changes.
Thus, the fabric to be treated may be reversibly passed from one to the other roller c and c' without dismounting the rollers by simply reversing the aforesaid mechanism.
Between the terminal guide rollers 2 and their corresponding rollers c and c' at each end of the apparatus, carrier rolls 79 are positioned as shown in FIG. 1. Sprockets 80 are carried by rolls 79 which are connected by chains 81 to the transmission mechanism t as shown in FIGS. 1, 11, and 12. The carrier rolls 79 have a rubber or the like surface and the sprockets 80 drive the rolls through axles 82. Arms 83 are mounted on the carrier rolls 79 which support satellite rolls 84 which extend parallel to rolls 79. Arm 83 has a toothed sector 85 on one side which meshes with a pinion 86 on a control shaft 87 that is driven by sprocket 88.
The fabric under treatment passes around the corresponding carrier roll 79, as shown in FIGS. 1 and 12, at each end of the machine. At the end of the apparatus at which the winding reel is located, e.g. reel c in FIG. 1, the satellite roll 84 is displaced upwardly to a position in which the fabric is wrapped over a greater amount of the surface of carrier roll 79, while at the opposite end of the apparatus, the satellite roll 84 is displaced in an arc downwardly to a position in which the fabric is wrapped over a smaller arc of the roller 79. The upwardly displaced position is shown in dot and dash in FIG. 12 and the downwardly displaced position is shown in solid. As already mentioned, displacement of each of the satellite rolls 84 is controlled by means of shaft 87 which is driven by sprocket 88 and whose pinion 86 meshes with the toothed sector 85 of arm 83.
Thus, when the satellite roll 84 is moved to its upper position at the takeup or winding end of the assembly, the area of contact with roller 79 is increased. The fabric is therefore grasped with greater friction at this roll, and is removed from the unwind roller c' and effectively drawn into the assembly over the roller 79 at the unwind end of the assembly. Since both rollers 79 rotate at the same speed, the fabric passing over guide rollers 2 is substantially untensioned.
Referring to FIG. 11, a satellite roll adjustment mechanism h is shown which surrounds the carrier roll 79. Mechanism h determines the final positions of the satellite roll displacement. Mechanism h includes end of run supports 89 and microswitches 90 that face a support arm 83. An operating handle 91 is connected with a rod 92 threaded into a bushing 93. The handle 91 is movable through a slot on the cover 94 the latter of which is fixed to the basic structure a. Thereby, the position of the microswitches 90 may be adjusted to determine the upper and lower limits of movement of the satellite roll 84. The sprocket 88 for transmitting movement to the control axle 87 of the satellite roll 84 is driven by way of an independent motor, rotation direction and starting and stopping of which is controlled by microswitches 90.
It is believed that the operation of the present invention will be clear from the foregoing description of the assembly. However, for purposes of clarity, a brief description of the operation of the assembly is as follows.
Prior to starting the assembly, the height of the grinding cylinders 3 is initially adjusted by way of hand wheels 17 such that the angle at which the fabric contacts the respective grinding cylinders is preset, as shown in FIG. 4, for the particular fabric and finishing result desired. A roll of the fabric to be processed is then mounted at roller c' as viewed in FIG. 1, and the control mechanism g is set so that locking pawl 77 engages notch 68 on piece 69 of jack mechanism b' and pawl 77 is disengaged from notch 68 on mechanism b, as shown in FIG. 1. Since roller c' will supply the fabric and will be an unwind roller at least initially, and roller c will act as a takup roller, the satellite mechanism of guide roller 79 at the left side of the machine will be operated to move the satellite roller 84 to the upper position to maximize the area of contact between the fabric and guide roller 79 and the satellite roller 84 at the right end of the machine adjacent supply roller c', will be moved to its lower position as shown in FIG. 1.
The assembly is now ready for threading. At this point push button 57, shown in FIG. 6, may be pushed to start the suction hood assembly 1 and push button 60 to start the machine. When the machine is started, motors 4 will drive the respective grinding cylinders 3 by way of belts 5 at a predetermined speed and in a predetermined direction as is desired for the conditioning of the particular fabric. Grinding cylinders 3 preferably rotate in a direction opposite to the direction of the travel of the fabric through the machine, but may, if desired, rotate in the same direction. Moreover, if desired, individual ones of the grinding cylinders may be made to rotate in opposite directions or at different speeds from other ones of the cylinders. In addition, the carrier rolls 79 will be driven at the same speed.
A conventional leader may now be attached to the leading end of the fabric on roller C' which is to be threaded. through the machine. This leader is threaded from roller c', between the lowered satellite roller 84 and carrier roll 79 at the right end of the machine as viewed in FIG. 1, beneath the grinding cylinders 3 and over the guide rollers 2, around roll 79 at the left end of the machine and the raised satellite roller 84, and onto the takeup roller c.
As shown in FIGS. 1, 9 and 10, the takeup roller c is driven by way of transmission t, chain 65, teeth 74, piece 72, portion 69 which is driven by the wedged rollers 76, axle 66, and chain 64, which drives plate 43 in assembly d, as shown in FIG. 5, which drives axle 33 and takeup roller 30. The speed of the takeup roller c is controlled by selectively porting air, as controlled by knob 54 shown in FIGS. 6 and 7, through conduit 48 to move thrust member 41 to cause friction surfaces 37 and 39 to engage plate 43 with a variable friction. Since plate 43 is being rotated by chain 64, a predetermined amount of this rotation will be imparted to annular members 36 and 38, depending upon the degree of slip between the plate 43 and friction surfaces 37 and 39. When winding is commenced on takeup roller c, roller c will be driven at a higher speed by porting more air through conduit 48 causing the friction surfaces 37 and 39 to firmly engage plate 43. As the diameter of the fabric on roller c increases, the rotational speed of the roller c is decreased by reducing the air pressure on thrust member 41 to cause slip between plate 43 and friction surfaces 37 and 39. In any event, the speed of the takeup roll c is controlled, such that it is just sufficient to collect the fabric which has been processed and maintain the fabric between roller c and the carrier roller 79 at the takeup end of the machine in a non-slackened condition. The actual movement of the fabric through the machine is caused by the pull exerted by the carrier roll 79 and raised satellite roll 84 at the takeup end of the machine. Since the speed of the carrier rolls 79 at the opposite ends of the machine is identical, the longitudinal tension on the fabric being processed between those rolls is negligible.
Conversely, the supply or unwind roller c' at the other end of the machine is disconnected from transmission t. Although chain 65 of the mechanism b' is being driven, pawl 77 is engaged in notch 68 causing rollers 76 to move to the solid position, shown in FIG. 10, thereby disengaging axle 66 from the continuously rotating portion 72. Thus, roller c' will not be driven by chain 64, but will be moved simply by the fabric as it is being withdrawn from the roller.
The speed of rotation of the unwind roller c' is accurately controlled also by selectively porting air, as controlled by knob 54 shown in FIGS. 6 and 7, through its conduit 48 so as to move the thrust member 41 causing friction surfaces 37 and 39 to engage plate 43. The speed of rotation of roller c' is variably controlled to prevent freewheeling by the amount of air pressure introduced to the thrust member 41. Since plate 43 is locked by the action of pawl 77 in mechanism b', introduction of air to thrust mechanism e will cause the friction surfaces 37 and 39 to slip against locked plate 43 to brake unwind roller c'. The tension between carrier roll 79 at the unwind end of the machine and roller c' will be minimal, since the area of contact of the fabric with driven roll 79 is minimized due to lowering the satellite roller 84 at the take off end of the machine. The rotating speed of roller c' will increase as fabric is removed from the roller and of roller c will decrease as fabric is collected and these speeds may be readily controlled by adjusting the braking or clutching forces exerted upon plates 43 by controlling the air pressure introduced through conduits 48 to the thrust members e of the rollers c and c'.
As the fabric moves through the machine at a constant predetermined speed as determined by the speed of carrier rolls 79, its upper surface will be ground by the rotative motion of grinding cylinders 3. In addition, as the grinding cylinders 3 rotate, such rotative force will be imparted, as shown in FIG. 3, through axle 20, pinion 21 and gear 22 to cause gear 22 to rotate. Since arm 24 is fixed at 25 at its other end, rotation of gear 22 will cause the gear and housing 26 to move back and forth as shown by the arrows in FIG. 3. Thus, the grinding cylinders 3 will not only rotate, but will be transversely oscillated at an oscillation rate which is a function of the rotation speed of the cylinders to prevent streaking of the fabric and substantially improve the quality of the final product.
Once the entire roll of fabric has been unwound from roller c', has passed through the assembly and has been collected on roller c, roller c may be removed if conditioning has been completed. However, if it is desired to pass the fabric back through the machine for repeated grinding, the machine may be simply reversed by pressing button 61 shown in FIG. 6.
Upon reversal, mechanism g is reversed such that pawl 77 engages notch 68 of mechanism b and disengages notch 68 of mechanism b'. Thus, roller c' will now become the takeup roller and will be driven by mechanism b' by way of chains 65 and 64. Conversely, mechanism b will be disengaged, since its rollers 76 will now move to the solid position shown in FIG. 10. The thrust mechanism 41 of assembly d at roller c will now be engaged as previously described with respect to the same assembly d of roller c' and the satellite roller 84 at the left end of the machine, as viewed in FIG. 1 will be lowered and satellite roller 84 at the right end of the machine will be raised. In addition, the direction of grinding cylinders 3 will be reversed by reversing their motors and carrier rolls 79 will be reversed due to reversal of tramsission t.
In FIG. 13 another embodiment of carrier and satellite roll construction is shown which differs from that shown in FIG. 12 in that this embodiment is manually operated, rather than automatically operated as in the embodiment shown in FIG. 12. The manual embodiment shown in FIG. 13 is mounted on the same structure a at each end thereof adjacent each of the carrier rolls 79.
In this embodiment, a rubber covered satellite roll 95 is mounted on a toothed sector 96. The sector 96 is angularly displaceable in an arc about a pivot pin 97 which is mounted to the structure a. The toothed sector 96 meshes with a pinion 98 which is coaxially mounted on a gear 99. A worm gear 100 is operated by a handwheel 101 and meshes with gear 99 such that when the handwheel 101 is rotated, gear 100 rotates gear 99 and its pinion 98 to drive the toothed sector 96 about its pivot pin 97 and, thereby, move the satellite roll 95 upward or downward relative to carrier roll 79 as previously described with respect to FIG. 12.
It should be understood that the embodiments of the present invention which have been described are merely illustrative of some of the applications of the principles of the invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | Apparatus for conditioning fabrics to alter the tonality and feel of the fabric includes a plurality of spaced guide rollers and rotating abrasion cylinders which are adjustable in elevation relative to the guide rollers. The abrasion cylinders also oscillate transverse to the direction of fabric travel in response to rotation of the cylinders. The tension of the moving fabric is readily controlled and the direction of travel of the fabric is reversible. | 3 |
REFERENCE TO RELATED APPLICATIONS
This application claims an invention which was disclosed in EPC application number 02425131.6, filed Mar. 7, 2002, entitled “HYDRAULIC TENSIONER OF THE HOLLOW PISTON TYPE WITH A SCREW-TYPE RETAINING DEVICE”. The benefit under 35 USC§119(a) of the EPC application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the field of devices for tensioning flexible drive transmission means, such as belts or chains. More particularly, the invention pertains to hydraulic tensioners. Reference will be made to transmission chains for internal combustion engines, such as are used to transmit motion from a first driving sprocket, operated directly or not by a vehicle engine, to one or more driven shafts, for example a cam shaft, fuel injection pump, or oil pump.
2. Description of Related Art
For reasons of adjustment, wear on materials and take-up of slack, it is often necessary to compensate for a certain slack of the chain and this is done by means of shoe tensioners, in which a shoe is biased with adjustable force against a chain side.
The bias on the shoe is normally obtained by a hydraulic tensioner. In its most widely known embodiment, a hydraulic tensioner comprises a cylinder-piston assembly. A stationary member (generally the cylinder) is mounted on the engine block, and a movable member (generally the piston) acts on the shoe under the action of a spring and hydraulic fluid, generally oil. In some known tensioners the piston is hollow and the piston chamber or bore receives a vent device sliding axially therein. The vent device has an end part that can be hemispherical or flat with a thin spiral groove on the face thereof facing toward the bottom of the piston, and the bottom of the piston has a through hole. The device is biased by the spring against the bottom of the piston and allows any air to exit or possibly oil to be discharged for lubrication purposes and to adjust the elastic-damping characteristics of the tensioner. The spring therefore acts between the cylinder and the disk and, through it, acts on the piston.
Some tensioners include a so-called “no-return” device, able to prevent re-entry of the piston into the cylinder if the oil pressure is lost and the action of the spring is not sufficient to maintain the piston in the correct position. The no-return device generally consists of a rack or toothed portion integral with the piston or in any case with the mobile member, which is engaged by a spring-biased toothed or ratchet locking pad.
Tensioners that can be fitted from the outside in the engine block or head, without any need to open the engine are called “cartridge” tensioners. EP-A-00830616.9, not yet published, describes a cartridge tensioner in which the rack portion is formed on the piston skirt. The ratchet pad is received in an opening in the cylinder skirt, with the possibility of axial sliding, and biased against the piston by a circular elastic band. For storage and shipping, before installation the piston is retained in a retracted position, in which only a small portion thereof extends from the cylinder, by engagement of a snap ring or circlip with an inside annular recess of the cylinder and an outside annular recess of the piston. To install the tensioner, it is necessary first to apply a force to the piston head which retracts it inside the cylinder for a length sufficient to move the retaining snap ring into a second, wider internal annular recess of the cylinder, so that the ring releases the piston. Although the solution provided in the aforementioned application is satisfactory for many applications, it nevertheless is not suitable in those situations where it is not possible or easy to apply the retraction force to the piston head.
U.S. Pat. No. 5,700,215 discloses a hydraulic tensioner having a cylinder and a solid piston or plunger movable inside the cylinder, in which a stopper screw for the piston is rotatably received in a through aperture of the cylinder wall and an internally threaded recess is formed on the inner end face of the piston. The screw, when engaged in the recess of the piston, retains the piston in a retracted condition, as can be required, for example, for maintenance purposes. This patent does not solve the problem concerning hollow piston or cartridge tensioners.
SUMMARY OF THE INVENTION
A cartridge tensioner for drive transmission belts and chains comprises a cylinder with a cylinder bore, a piston slidably received in the cylinder bore and provided with a piston bore, a vent device housed in the piston bore and comprising an end part and a stem integral with each other, a pressure spring acting between a shoulder of the cylinder and the vent device, and a retaining device, accessible from the outside of the cylinder. When the retaining device is in a position engaged with the stem of the vent device, it retains the vent device, and prevents the action of the spring on the piston. When the retaining device is in a position of disengagement from the stem of the vent device, it allows the spring to bias the device against the piston and to act consequently on the piston. In a preferred embodiment, the end part is disc-shaped or convex.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagrammatic illustration of a chain transmission provided with a cartridge tensioner.
FIG. 2 shows an axial sectional view of a cartridge tensioner according to the invention, in a retracted or rest position, with its retaining screw engaged in the stem.
FIG. 3 shows an axial sectional view of the tensioner of FIG. 2 , wherein the tensioner is illustrated in an operative condition, with the retaining screw disengaged from the. stem, and with the piston in a retracted position inside the cylinder.
FIG. 4 shows an axial sectional view of the tensioner of FIGS. 2 and 3 , in an operative condition with the piston at its maximum extension.
FIG. 5 shows an axial sectional view of another embodiment of the tensioner of the invention, in which the tensioner is illustrated in the rest position.
FIG. 6 shows an axial sectional view of another embodiment of the tensioner in a rest condition; the tensioner has no toothing of the piston and no ratchet pad.
DETAILED DESCRIPTION OF THE INVENTION
The present invention shows a cartridge tensioner with a retaining device, which can be applied in those situations where it is not possible or easy to apply an initial retracting force to the piston head.
The tensioner of the present invention includes a cylinder, a retaining valve for the hydraulic fluid in the cylinder, a hollow piston movable inside the cylinder and having a piston bore, a vent device inside the piston bore, a pressure spring between the cylinder and the vent device, and a retaining device, preferably a stopper or retaining screw, rotatably received in the cylinder and in screwing engagement with a stem part of the vent device. The retaining screw is preferably disposed coaxially to the cylinder and is accessible from the opposite end thereof to that from which the piston protrudes.
When the retaining screw is screwed completely into the stem, the disc is retained in a retracted position in which the spring cannot act on the piston. When the screw is disengaged from the stem, the spring biases the disc against the piston head, and thus acts on the piston, and the device operates in the traditional manner. The tensioner is preferably of the type comprising a longitudinal toothed portion of the piston and a ratchet retaining element or pad spring biased in engagement with the toothed portion or rack of the piston.
The retaining device of the invention acts only on the spring, leaving the piston exposed to other forces. However, friction between the piston rack and the ratchet pad, if provided, when the spring action is eliminated, is generally sufficient to retain the piston. If necessary, moreover, an engagement or interference between the piston bore and the vent device can be foreseen, to retain the piston.
Now referring to FIG. 1 , a chain ( 1 ) is shown therein, which is wound on a driving sprocket ( 2 ) and a driven sprocket ( 3 ). The taut side (the lower one in the figure) is guided by a guide ( 4 ). A tensioner shoe ( 5 ) acts on the slack side (the upper one in the figure). The shoe ( 5 ) is mounted to oscillate around a pivot ( 6 ) and is biased against the chain by tensioning device ( 10 ).
Referring also to FIGS. 2 through 4 , the tensioner ( 10 ) of the present invention comprises a cylinder ( 12 ), a piston ( 14 ), a vent device ( 16 ), a spring ( 18 ) and a retaining device ( 20 ). The cylinder ( 12 ) includes a cylinder skirt ( 21 ), a cylinder head ( 22 ), and a cylinder bore ( 23 ). An outer thread ( 24 ) on the skirt screws the cartridge tensioner into position in the engine block. The skirt is interrupted by a through aperture ( 25 ) which receives a toothed or ratchet pad ( 26 ), preferably of the type described in application EP-A-0083066.9, biased elastically toward the axis of the cylinder by an elastic band ( 27 ).
The cylinder head ( 22 ) has a passage ( 28 ) coaxial with the bore ( 23 ) and in communication therewith, open toward the outside. Two housings ( 29 ) and ( 30 ) disposed with their axis (b) transversal to the axis (a) of the cylinder bore ( 23 ) receive a check valve ( 32 ) and a spiral pin ( 34 ), respectively. The valve ( 32 ) is preferably of a known type and therefore will not be described in detail. The pin ( 34 ), also of a known type, has a thin spiral groove ( 35 ) on a cylindrical surface thereof and is used to allow the passage of air during start-up of the device. The pin ( 34 ) also allows a controlled loss of oil, to define the dynamic elast-dampening characteristics of the tensioner.
The piston ( 14 ) is hollow, has a piston bottom ( 36 ) with a central through hole ( 37 ) in a known manner, and a piston skirt ( 38 ) which defines a piston bore ( 40 ) on the inside. The piston skirt has a rack toothing ( 42 ) which cooperates with the toothing of the ratchet pad ( 26 ) in a known manner, to allow an extension movement of the piston from the cylinder bore ( 23 ) and to prevent a return movement of the piston inside the cylinder bore.
The piston bore houses the vent device ( 16 ), which includes a end part ( 44 ) that controls passage of air, and a stem ( 46 ), integral therewith. The end part ( 44 ) is preferably disc-shaped or convex (for example hemispherical). The stem of the device has, at the opposite end to the disc, a threaded axial hole, or recess ( 47 ).
The pressure spring ( 18 ) extends between a face of the vent device ( 44 ) and a bottom wall ( 13 ) of the cylinder bore ( 23 ).
The retaining device or screw ( 20 ) comprises a head ( 48 ) and an integral threaded stem ( 49 ). The head ( 48 ) is received in the passage ( 28 ) so as to be able to rotate therein around the axis (a). The head ( 48 ) has a neck ( 48 ′) that defines a seat for an O-ring type liquid seal ring ( 50 ). A snap ring ( 54 ) is received in a circumferential groove of the screw device ( 20 ) to retain the screw axially in one direction against a shoulder of the cylinder head. In the opposite direction, the screw is retained because the check valve ( 32 ) and the threaded pin ( 34 ) protrude inside the passage ( 28 ) for such a distance as not to allow the passage of a flared screw body portion, and because the screw head abuts against the cylinder head.
Operation of the tensioner is now described. The tensioner ( 10 ) is shown in a rest or installation condition in FIG. 2 . The threaded stem ( 49 ) of the screw ( 20 ) is screwed into the stem ( 46 ), so that the vent member or device ( 16 ) is maintained in a constrained retracted position in which it keeps the spring ( 18 ) compressed. The piston ( 14 ) is subject during handling and installation operations only to the action of its own weight. The elastic band ( 27 ) is calibrated so that the friction between the piston teeth ( 42 ) and the teeth of the pad ( 26 ) can withstand the action. If required, it is possible to combine this action with that of a friction assembling (“driving”) of the piston ( 14 ) and the disc ( 44 ).
By unscrewing the screw ( 20 ), which can be done easily by maneuvering a screwdriver from the end of the cylinder illustrated on the left in the figures, the stem member ( 16 ) is released from the screw device ( 20 ). This condition is shown in FIG. 3 . The action of the spring ( 18 ) then brings the disc ( 44 ) against the bottom ( 36 ) of the piston and thereafter the action of the spring is applied to the piston. Consequently, the piston, overcoming the friction, tends to extend out of the cylinder and apply a bias to the tensioning shoe (not shown). The piston is shown in the condition of maximum extension from the cylinder in FIG. 4 .
In an alternative embodiment shown in FIG. 5 , the elements corresponding to those of the preceding figures are denoted by the same reference numerals, and will not be further described in detail. The tensioner ( 10 a ) of FIG. 5 differs from the tensioner ( 10 ) of the preceding figures essentially in that the screw device ( 20 a ) is retained axially, not by engagement of the snap ring ( 54 ) against a shoulder of the cylinder head passage, but by ridges ( 56 ) of the screw shank, and by a widened portion ( 55 ) thereof, which engage with inward protruding end parts of check valve ( 32 ) and of spiral pin ( 34 ). Operation of the device ( 10 a ) is similar that of the device ( 10 ) and will not be further described.
FIG. 6 shows an alternative embodiment ( 10 b ) of the tensioner in which a retaining screw device ( 20 a ) similar to that of FIG. 5 (but it could also be the device ( 20 ) of FIGS. 2–4 ) is applied to the stem of a vent device ( 16 b ) that cooperates with a piston ( 14 b ) without side toothing. The members of the tensioner ( 10 b ) identical to those of the tensioners of the preceding figures are denoted by the same reference numerals and will not be described in detail. The disk ( 16 b ) preferably interferes with a portion of the inner surface of the skirt of piston ( 14 b ) so as to be able during handling and assembly operations to retain the piston when only the action of its own weight and not that of the spring ( 18 ) is applied thereto, that is in the rest condition illustrated in FIG. 6 .
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | A cartridge tensioner ( 10 ) for drive transmission belts and chains comprises a cylinder ( 12 ) with a cylinder bore, a piston ( 14 ) slidably received in the cylinder bore and provided with a piston bore ( 40 ), a vent device ( 16 ) housed in the piston bore and comprising an end part and a stem integral with each other, a pressure spring ( 18 ) acting between a shoulder of the cylinder and the vent device, and a retaining device ( 20 ), accessible from the outside of the cylinder. The retaining device, in a position engaged with the stem of the vent device, retains the vent device preventing the action of the spring on the piston, and, in a position of disengagement from the stem of the vent device, allows the spring to bias the device against the piston and to act consequently on the piston. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an adapter for installation around an existing handle in a manner such that the user of the handle can mold the outer portion of a handle so equipped to fit his (her) grip. The handling of the item provided with such handle is thereby greatly facilitated and rendered much firmer and more precise. This is done by enabling the user to cause the external contour of the adapter to conform to his (her) grip and to maintain such conforming shape.
As a typical example of a class of items which could benefit from the application of the present invention are those items requiring a firm and exact grip and onto which externally and randomly applied loads are the result of their very use. Cases in point are a golf driving club and a tennis racket. In both cases, the item must hit an object correctly and hitting the object causes forces to be applied on the item, forces which in most instances are negatively disturbing. Such forces generate torques on the item handle, torques that the user must counteract and which necessitates a firm grip on the handle.
Attempts have been made in the past for providing such grip enhancers such as wrapping leather straps around the handle, having a mold made of the user grip for later shaping the handle and coating the handle external surface with materials offering good friction qualities. Having a mold made of one's hand grip is expensive. Means for increasing friction do not provide the handling precision expected and needed from the grip.
Thus a new inexpensive and effective way to adapt a specially and personally molded "handle-grip" to an existing handle is needed. The goal of the present invention is to provide such a way, in a manner such that the user alone can equip the handles of his favorite items.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a moldable adapter that can be easily and securely installed on an existing handle.
It is another object of the present invention to provide a moldable adapter that fits the shape of the natural grip of a hand when it performs the act of firmly gripping.
It is still another object of the present invention to provide a moldable adapter that can be made to fit the user's grip in more than one way to hold the handle during the use thereof.
It is still another object of the present invention to provide a moldable adapter that has an external surface which can be selected to fit the touch characteristics most pleasant and most effective for the user.
Accordingly, the present invention provides a moldable adapter for handles that is easy to install, simple and inexpensive, and which offers selections of moldable materials and/or cover materials deemed most suitable for giving to the user the "feel" and the "touch" which are most desirable to him (her).
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan longitudinal sectional view of two assembled halves of the pouch.
FIG. 2 is a partial elevation view of the end of the smaller half pouch.
FIG. 3 is a partial elevation view of the end of the larger half pouch.
FIG. 4 is a partial plan sectional view of the joint between the halves of the pouch and of the clamp thereon.
FIG. 5 is a partial elevation sectional view of the joint between the halves of the pouch and of the clamp thereon.
FIG. 6 is a cross-sectional view of the joint between the two halves of the pouch and of the clamp thereon.
FIG. 7 is a partial longitudinal sectional view of the pouch shown partially installed on a handle.
FIG. 8 is a longitudinal sectional view of the adapter on the handle and being molded by the user's fingers.
FIG. 9 is a partial view of the wall of one end closure of the pouch showing the sealing means of the aperture used for access to the internal volume of the pouch.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 6, the adapter, in its moldable form consists of a larger half pouch 10 joined to another smaller half pouch 12 by lap joint 14 formed by the overlapping of walls 16 and 18. The two half pouches are closed by end closures 20 and 22 specially shaped so as to facilitate the swelling of the half pouches as needed to accommodate the increases in their internal volumes caused by the introduction of the handle therein.
The pouch is filled with a moldable paste-like fluid, which is not shown for the sake of simplicity, occupying a volume considerably smaller then that which the pouch could contain if totally inflated. As an example, it is asumed, in the case of FIGS. 4 to 6, that the fluid consists of two parts which, when brought into intimate contact, react to form a mixture which rapidly hardens. For that reason, in their moldable state, the contents of the two half pouches must be separated and kept isolated until application is shortly forthcoming. FIGS. 4 to 6 depict a clamp configuration applied onto the half pouch lap joint 14. Clamp 24, shown in a deformed clamping shape, applies pressure on lap joint 14, thus preventing contact between the contents of the two half pouches. The original shape of clamp 24 is shown in phantom lines 25 in FIG. 6, before the jaws 26 and 28 of a crimping tool, not shown, were used to effect the clamping.
Referring to FIG. 7, the smaller pouch wall 18 is shown being wrapped against a handle core 30, assuming that clamp 24 has beem removed and that mixing the contents of the two half pouches has already been achieved. When the handle core becomes fully wrapped inside the sheath formed by walls 16 and 18, as shown by phantom line 32 of FIG. 1 (molded adapter), the moldable content of the sheath is ready to be molded into the wanted shape.
The molding operation is represented in FIG. 8 in which handle core 30 is shown enveloped by the sheath with an internal volume 33 filled with the moldable material. While the material is still in its plastic stage, pressure is then applied by fingers 11, 13, 15, 17 and thumb 19 of a hand (not shown) onto wall 16. The pressure then developed in volume 33 causes wall 16 to bulge slightly within the boundary constraints formed by the hand and the slight deformations of wall 16, and is transmitted to wall 18 supported by the external surface of handle core 30, thereby insuring a firm contact later between the molded adapter and the handle core. The construction of the pouch is such that lap joint 14 remains on the external wall of the molded adapter, thereby avoiding the necessity of a very flexible lap joint. For reference, contour 35 shown in phantom lines indicates how the moldable adapter is first engaged.
Depending upon the method used for filling the pouch with its contents, either one or two end closures are equipped with a filling orifice 36 located on the end closure (see FIG. 9). This orifice (or aperture) is sealed by specially shaped plug 38 which becomes firmly held once inserted in the aperture.
DISCUSSION AND OPERATION
The handle adapter just described can be constructed to be installed on a vast range of items and tools which need handling in a precise and firm manner. Also it can be constructed to accommodate handles that must be held with one hand or two hands. Furthermore, in some applications, the handle may be held in one hand only, but differently according to the type of function to be served. As an example, a tennis racket may be held in at least three basic ways. Each way requires a different holding of the racket. A golf driving club must be held with two hands, placed in one specific manner relatively to one another. Numerous other applications could also be enumerated and discussed, however the application scope of the present invention is too wide to even attempt it. The content of the following discussion, therefore, should not be construed as a limitation of such scope.
The three basic components of the adapter are the pouch, the material contained therein and the clamp. Each component is discussed separately below.
THE COMPOSITION MATERIAL
When molded, the material becomes one monolithic homogeneous hard body. The transition from moldable material to molded material must be made possible only once, at any time chosen by the user, be irreversible and achievable in a period of minutes. Also, the transformation of moldable to molded must be permanent and not influenced by time. The transformation, triggerred at will by the user, must only require a simple operation by the user. Because the molding must necessarily be accomplished by hand, the use of temperature as the transformation triggering agent is not practical. A chemical reaction between two base constituents is favored, but should not be construed as a limitation. Two types of chemical reactions are used as typical and non-limitative examples. One requires the use of a clamp, the other may not.
A well-known chemical reaction which does not require the use of a clamp to prevent the two parts of the chemical composition from coming into contact prematurely is that of water with plaster of Paris. The pouch contains a set amount of plaster of Paris powder and reinforcing fibers (glass fibers for instance) and is evacuated. The pouch can be pierced with the needle of a syringe containing a set amount of water when the user decides to mold the adapter around the already prepared handle core, at which time, the water is injected into the pouch for mixing with the pouch content. The user can then manipulate the pouch wall so as to throughly cause the plaster of Paris, the fibers and the water to form a paste that will harden in a few minutes. During these few minuts, the user then causes the smaller half of the pouch to roll over the handle core and then the larger half of the pouch to slide over the wall of the smaller pouch, while the material is still fluid. When the user senses the start of the hardening process by touch and finger pressure, he then forms the type of grip he selects and maintains that grip. As the user maintains his (her) grip, the hardening material assumes the shape imposed onto the pouch wall by the gripping hand. After a few more minutes, the plaster has set and the grip may be released. The molding of the adapter is completed, it has passed from the moldable stage to the in-place molded stage.
Another typical way to form a hard body in-place by hand molding is to cause two parts of a resin composition to become intimately mixed within a closed flexible-walled container. Such a composition is used as a typical and non-limitative example for the present invention construction in the case where a clamp is required to prevent premature contact between the two parts. The nature of the composition is unimportant and the two parts are referred to as Part A and Part B. In such construction, Part A may be contained in the smaller half pouch and Part B may be contained in the larger half pouch. The end closures of both half pouch are equipped with an aperture. After the the two half pouches have been assembled and the lap joint sealed, the clamp is placed on the joint. Each part of the composition is then injected in its respective half pouch, while being kept evacuated. After the correct amounts of Part A and/or Part B have thus been injected, plugs 38 are set in place to seal the half pouches. The moldable adapter is ready for storage until use is needed.
When a user decides to mold the adapter around an already prepared handle core, he (she) loosens the clamp and removes it. Squeezing alternatively each half pouch and forcing the content therein to flow into the other half pouch and pursuing such manipulation for a fraction of a minute results in a thorough mixing of the two parts. At that time, the operation of inserting the handle core into the pouch may be started and then completed in a short time, before the composition has appreciably hardened.
The user can then apply and maintain his selected grip type on the adapter external wall in the manner above-indicated. Chemical compositions such as some epoxy resins harden sufficiently in a few minutes, enough time to give the adapter its molded shape. To prevent this shape from changing noticeably during the period of time required for the completion of the resin curing, care is taken to rest the handle in a position such that any subsequent deformation of the molded resin is minimized and remains localized in a portion of the adapter which is least critical.
THE CLAMP
The clamp function is to keep both parts of a two-part composition segregated until such time when they must be mixed. The nature of the material used in the construction of the pouch walls is such that it is pliable, flexible, remains so with time and does not stretch much. The pressure applied onto the joint by the clamp needs only be small, not too localized but well distributed along the joint fold so as to effectively seal the passage between the two half pouches. When in place, the clamp must be easily removable with a minimum amount of effort and without risk of causing damage to the pouch walls. This can be achieved as is well known in the art by creating a weak point in a highly stressed part of the clamp, such as points a and/or b shown in FIG. 6 as examples.
The need for a clamp can be altogether eliminated with the use of a pressure-sensitive sealing seam located on the internal surface of wall 18 of the smaller half pouch. The location and extent of such a sealing seam are depicted by phantom lines c of FIG. 1. Such a seam seal consists of a narrow band coated onto the internal surface of wall 18, as shown, with a pressure sensitive adhesive as is well known in the art. The sealing occurs when the joint between the two half pouches is formed by flattening the already positioned open ends of the half pouches in the manner described for crimping the clamp in place. The internal seal thus created is much weaker than the much wider seal joining the two half pouches. When the content of one half pouch is forced by hand-applied pressure to push onto the internal seal, the seal ruptures and opens the passage between the two halves. If hand pressure is applied first on the smaller half pouch, the risk of damaging the joint seal is eliminated altogether. In such a construction, the clamp is not needed and the user's task is substantially simplified and rendered very easy.
THE POUCH
The nature of the materials used to fabricate the walls of the two half pouches need not be the same. As a matter of fact, each wall has its own set of requirements when the adapter is used in the molded stage. The external surface of wall 18 should adhere well to the handle core external surface. The external surface of wall 16 should offer good friction between the adapter and the user's hand. The external surface of wall 18 and the internal surface of wall 16 must form a strong lap joint when brought in contact to construct the adhesion sealing joint. An adhesive compatible with the materials of the walls can be used as is well known in the art. Heat-induced welding by means of localized fusing of compatible materials can also be used. Thus, the construction of the lap joint is achievable in ways that do not impose undue constraints on the selection of materials for the pouch walls.
These walls are in direct contact with at least one part of the composition material. Long storage life must be possible prior to use. The number of compatible combinations of composition materials and of wall materials is large as is well known in the art. The last and most important requirement imposed on the choice of wall material is that of providing a good "feel" to touch and good friction with hand skin, even while sweating. A suede-type of finish is possible with some plastic. The external surface of wall 16 can also be spray-coated with a finish coating that incorporates pieces of natural fibers which could provide friction, the right "feel" and also minimize the sweat problem. The wall materials must also be impervious to and serve as a barrier to gases and/or vapors that may be generated by the composition parts, before they are mixed. In all instances, the internal cavities formed by the half pouches must not contain trapped air and sould be evacuated. In the construction where plaster of Paris and an internal seam seal are used, water can be stored in one of the two pouches. Although voids necessarily exist between dust particles and/or fibers, such void volumes could also be evacuated.
The closing and sealing of the end closure apertures can easily be performed by providing an adequate flexible seal such as shown by d of FIG. 9, to maintain the vacuum. The insertion of sealing plug 38 can be facilitated by shaping its gland e as is represented in FIG. 9, plug 38 being also referred to as sealing cap. Once the sealing capped plug 38 is set permanently in place, any pressure exerted by the fluid inside the elongated container during the kneading action of walls 16 and 18, pushes gland e against the internal edge of orifice 36, thereby providing the sealing action needed for preventing any fluid leakage. Conversely, air is preventing from being sucked in by seal d formed by lip f of the cap. If plug 38 is installed by the user, upon filling the pouch, a protective peel-off guard (not shown) may be removed, exposing a pressure sensitive adhesive, located either on the internal face of the cap or around the orifice edge on the external surface of the end closure. Setting the capped plug in place then automatically creates a bond and the seal.
ALTERNATE EMBODIMENTS OF THE INVENTION
When a chemical composition consists of two parts, the relative amount of each part may vastly differ. In such an instance, the amount of the least voluminous part (usually a small percentage of the volume of the other part) is called and acts as a catalyst for a chemical reaction that takes place within the fluid of the most voluminous part. A potentially possible reaction is thus triggered and proceeds on its own henceforth once triggered. Such chemical reaction is best known as molecule cross-linking. It can happen typically with some types of plastic resins and silicone rubbers. Because the amount of catalyst is so small, but so powerful, it must absolutely be kept from contacting the other fluid and still be immersed in the fluid to be catalyzed, in the case of the present invention. This can be done by encapsulating the catalyst in a liquid form in a small container having thin flexible walls impervious to both the liquid catalyst and its vapor. The capsule is then placed inside the elongated pouch as depicted in FIGS. 1 and 4 by phantom lines h. When hardening of the fluid is desired, the catalyst capsule can be squeezed between two fingers through wall 16 (or 18) and caused to rupture, thusly injecting the catalyst into the fluid. At that time, the kneading operation of the pouch walls needed to cause a good mixing of fluid and catalyst can be performed. The shearing forces within the viscous flow of the fluid back and forth in the elongated pouch provide the mixing action required.
Both plastic resin and silicone rubber materials can be used in both embodiments: (1) when the two parts are of substantially equal volumes (reaction between two chemicals), and (2) when a cross-linking reaction is triggered by the use of a catalyst. In both cases, the fluid(s) which compose the bulks of the adapter body material can be inserted by the user immediately prior to their mixing, through one single orifice such as 36. This can be best performed with the use of two squeezable tubes provided with the elongated container equipped with its removable capping plug. The tubes each have a pointed discharge spout which can easily be inserted in the orifice. Each contains one of the two complementary parts of the fluid. The need for a clamp or for a sealing seam is eliminated. If a catalyst is used, the catalyst capsule can be located any place inside the pouch, and the fluid can then be added by the user in the manner above described. The sealing plug can then be permanently installed. The user ruptures the capsule and then mixes fluid and catalyst. The use of squeezable tubes for storage of the fluid prior to use improves the shelf life of the fluid and increases greatly the number of types and selections of materials then usable for walls 16 and 18.
The above-described embodiment also simplifies the construction of the elongated container. Lap joint 14 can be located near one end closure. Depending upon whether it is preferable or not to keep the lap joint exposed after installation of the adapter, the slip joint can be located closer to end closure 22 or 20. As selected, the lips of the end closure and the lips of the elongated pouch can also be joined together to form a lap joint. But the choice of construction of such end closure can best be left up to the manufacture to best satisfy the requirements of each specific application contemplated for the adapter.
In the case of all embodiments, the handle core must be prepared to receive the adapter. Such a preparation is left to the user to perform. In all instances, the molded adaptor must provide a positive and permanent locking of the adapter in place. In its moldable stage, the adapter is quite deformable and can conform to varied shapes and sizes, within limits. According to guiding directions, it is up to the user to chose and adopt the combinations of shape, size and degree of finish he thinks best. It is even possible for him to shape the handle core in a manner such that the molded adapter becomes removable and adaptable to other handles. A flexibility of adaptation of the molded adapter to various item handles by a user can easily be provided by the present invention.
As earlier explained, the invention refers to either a moldable or a molded adapter. The invention pertains to the same configuration, but at two different stages of its construction. The moldable configuration has no permanent shape, the content of the elongated container or pouch is in the form of a viscous fluid, even when the mixing of the parts has taken place, at least for a short time. After the moldable configuration is installed on the handle core, it is still in its moldable stage for a short while, long enough to enable the user to select and form his grip (or his two or three basic types of grips, as the case may be). The user must then maintain the grip until the adapter gives a feel of hardness, the "plastic" feeling earlier felt is then gone and it would be difficult to modify substantially the form then given to the adapter. The adapter has then acquired its molded configuration which has become permanent. The two terms apply to the invention equally well. In the cases where plastic resins or silicone rubbers are used, the adapter remains moldable after a substantial amount of curing has taken place. The adapter becomes molded before most of the curing process is completed.
Regardless of the nature of the chemical composition used in the adapter, the installation of the pouch around the handle core proceeds in the same manner as earlier described. It is better to perform the installation as soon as the fluid mixing is finished and before appreciable thickening occurs, so as to facilitate the sliding of th outer wall along the inner wall. For some compositions, the use of limited heat can lower the viscosity of the fluid for a short while and be very helpful. However, heat accelerates the curing process and reduces the amount of time available to the user for forming the adapter. Conversely, cooling the composition slows down the curing process and increases the viscosity of the fluid, thereby providing more time for the forming operation. A specified stage of the hardening, after which altering the adapter shape becomes impractical and the material will not change its form, is defined for each composition and corresponds to the degree of local deformation that locally exerted pressure can cause (touch feeling). When such a specified stage is reached, the equipped handle can be placed in a vertical position so as to minimize the effects of any residual creeping of the material.
It is thought that the apparatus and the method of the present invention will be understood from the forgoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention. | A handle adapter for hand molding around an existing handle and constructed in a manner enabling the user to shape the external surface of the adapter to conform to the grip of the user's hand. The material to be molded is contained in a pouch having flexible walls and end closures. The size of the pouch is such that the total volume which it could contain is much larger than the volume of the moldable material therein. One half of the pouch has a cross-sectional area smaller than the cross-sectional area of the other half, whereby the smaller cross-section half of the pouch can be pushed inside the larger cross-section half of the pouch and the material therebetween becomes trapped between two concentrically positioned flexible walls. When the walls of the smaller half pouch are supported by a solid structure, the moldable material then envelops such structure. When pressure is applied externally preferentially at certain locations on the walls of the larger half pouch, the trapped moldable material has no way to escape and is forced to rearrange its shape to match the external contour imposed on the outer wall on which such pressure is being applied. The moldable material is then caused to harden while the pressure remains applied. This results in obtaining a molded external surface which thus matches the configuration of the means by which the pressure was externally applied. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The subject application is related to subject matter disclosed in the Japanese Patent Application Tokugan2000-85050 filed Mar. 24, 2000 in Japan, to which the subject application claims priority under the Paris Convention and which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to electric characteristic evaluating apparatus, electric characteristic evaluating method and electric characteristic evaluating program for extracting electric characteristics of a semiconductor device by numerically solving physical equations describing the physical phenomenon in the semiconductor device, and also a semiconductor device manufacturing method for determining manufacturing conditions of semiconductor device from the extracted electric characteristics and manufacturing a semiconductor device on the basis of the determined manufacturing conditions, and more particularly to a technology of curtailing the term and expenses of semiconductor manufacturing process by identifying the generation and extinction mechanism of the carrier for determining the leak current in the semiconductor device by a single calculation, and shortening the time required for evaluation of electric characteristics.
[0004] 2. Description of the Related Art
[0005] Leak current is known as one of the electric characteristics that determine the performance of a semiconductor device, and, for example, the pause characteristic of DRAM and power consumption of SRAM are determined by, the leak current of the semiconductor device which composes a memory cell. Generally, the bias condition of semiconductor device depends on the specification of the semiconductor device, and it is hard to set freely, but since the distribution of impurity concentration or device shape can be controlled by the manufacturing method and manufacturing conditions of the semiconductor device, the leak current can be controlled by optimizing the distribution of impurity concentration or device shape.
[0006] In such background, recently, by numerically solving the physical equations described in nonlinear differential equations such as Poisson's equation or current continuous formula in consideration of distribution of impurity concentration of semiconductor device or device shape, it has been attempted to evaluate the leak current by using a device simulator (=electric characteristic evaluating apparatus) for extracting and evaluating the electric characteristics of semiconductor device. When evaluating the leak current by using the device simulator, the generation and extinction mechanism of the carrier which is the source of leak current must be taken into consideration, and principal mechanisms include SRH (Shockley-Read-Hall) process, impact ionization, and inter-band tunneling. Therefore, by using the device simulator, the generation and extinction mechanism as the principal cause of leak current can be recognized, and therefore by identifying the principal cause of leak current, proper measures for reducing the leak current can be taken before manufacturing the semiconductor device.
[0007] However, the evaluation process of leak current using such conventional device simulation technology involves the following technical problems to be solved.
[0008] That is, in the conventional process, in order to identify what is the generation and extinction mechanism to reign the leak current, it requires plural times of execution of device simulation, and, for example, when evaluating the leak current in consideration of three mechanisms of carrier generation and extinction, that is, SRH process, impact ionization, and inter-band tunneling, device simulation must be executed three times in order to calculate the leak current due to SRH process only, leak current due to impact ionization only, and leak current due to inter-band tunneling only, and it needs further execution of multiple times of device simulation if considering also other leak current mechanism, such as generation and extinction mechanism of carrier at the interface of semiconductor and insulator.
[0009] Yet, generally, if attempted to optimize the impurity concentration and device shape in order to reduce the leak current by making use of device simulation technology, the device simulation must be executed plural times, and in such situation, further, if desired to evaluate by separating the contribution of leak current about generation and extinction mechanism of each carrier, it needs three times of execution of device simulation.
[0010] Thus, the evaluation of leak current by using the existing device simulation technology requires numeral repetitions of execution of device simulation until the desired information is extracted, and it takes too much time in evaluation of electric characteristics, and it was hence difficult to curtail the term and expenses of manufacturing process of semiconductor device.
SUMMARY OF THE INVENTION
[0011] The invention is devised in the light of such technical problems, and it is hence an object thereof to curtail significantly the term and expenses of manufacturing process of semiconductor device.
[0012] To solve the technical problems, the present inventor integrated the carrier generation and extinction speed obtained by numerically solving physical equations, in each carrier generation and extinction mechanism within the semiconductor region, estimated quantitatively how much is contributed to the leak current by each carrier generation and extinction mechanism by a single simulation for output of integral value, and learned that the time required for evaluation of electric characteristic can be substantially curtailed, so that the term and expenses of manufacturing process of semiconductor device can be curtail, and thereby continued intensive studies and finally reached the technical concept having the following features.
[0013] The first feature of the present invention is an electric characteristic evaluating apparatus for extracting electric characteristics of a semiconductor device by numerically solving physical equations describing physical phenomenon in a semiconductor device, which comprises an integral value calculator for integrating the carrier generation and extinction speed obtained by numerically solving the physical equations, in each carrier generation and extinction mechanism within the semiconductor region, and issuing the result obtained by integration.
[0014] Hence, the time required for evaluation of electric characteristics can be shortened, and the term and expenses of manufacturing process of semiconductor can be substantially curtailed.
[0015] The second feature of the present invention is an electric characteristic evaluating method for extracting electric characteristics of a semiconductor device by numerically solving physical equations describing physical phenomenon in a semiconductor device, which comprises an integral value calculating step of integrating the carrier generation and extinction speed obtained by numerically solving the physical equations, in each carrier generation and extinction mechanism within the semiconductor region, and issuing the result obtained by integration.
[0016] Hence, the time required for evaluation of electric characteristics can be shortened, and the term and expenses of manufacturing process of semiconductor can be substantially curtailed.
[0017] The third feature of the present invention is an electric characteristic evaluating program for extracting electric characteristics of a semiconductor device by numerically solving physical equations describing physical phenomenon in a semiconductor device, which comprises an integral value calculating process of integrating the carrier generation and extinction speed obtained by numerically solving the physical equations, in each carrier generation and extinction mechanism within the semiconductor region, and issuing the result obtained by integration, and makes a computer execute this process.
[0018] Hence, the time required for evaluation of electric characteristics can be shortened, and the term and expenses of manufacturing process of semiconductor can be substantially curtailed.
[0019] The fourth feature of the present invention is a semiconductor device manufacturing method for extracting electric characteristics of a semiconductor device by numerically solving physical equations describing physical phenomenon in a semiconductor device, determining the manufacturing conditions of semiconductor device from the extracted electric characteristics, and manufacturing the semiconductor device on the basis of the determined manufacturing conditions, which comprises an integral value calculating step of integrating the carrier generation and extinction speed obtained by numerically solving the physical equations, in each carrier generation and extinction mechanism within the semiconductor region, and issuing the result obtained by integration, and a step of determining the manufacturing conditions of the semiconductor device having the desired electric characteristics on the basis of the output of the integral value.
[0020] Hence, the time required for evaluation of electric characteristics can be shortened, and the term and expenses of manufacturing process of semiconductor can be substantially curtailed.
[0021] Other and further objects and features of the present invention will become obvious upon understanding of the illustrative embodiments about to be described in connection with the accompanying drawings or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employing of the invention in practice.
BRIEF DESCRIPTION OF DRAWINGS
[0022] [0022]FIG. 1 is a block diagram showing a configuration of semiconductor device manufacturing system according to an embodiment of the present invention.
[0023] [0023]FIG. 2 is a flowchart showing a semiconductor device manufacturing method according to an embodiment of the present invention.
[0024] [0024]FIG. 3 is an outline view showing a configuration of an electric characteristic evaluating apparatus according to an embodiment of the present invention.
[0025] [0025]FIG. 4 is a diagram showing design information of a semiconductor device.
[0026] [0026]FIGS. 5A,5B are the diagram showing result of experiment by using electric characteristic evaluating methods of prior art and the present invention.
[0027] [0027]FIGS. 6A,6B are the diagram showing result of experiment by using electric characteristic evaluating methods of prior art and the present invention.
[0028] FIGS. 7 A˜ 7 H are the equation which is used in a semiconductor device manufacturing method according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Various embodiments of the present invention will be described with reference to the accompanying drawings. It is to be noted that the same or similar reference numerals are applied to the same or similar parts and elements throughout the drawings, and the description of the same or similar parts and elements will be omitted or simplified.
[0030] (Electric characteristic evaluating apparatus)
[0031] [0031]FIG. 1 is a block diagram showing a configuration of semiconductor device manufacturing system according to an embodiment of the present invention.
[0032] An electric characteristic evaluating apparatus 11 of the present invention is connected to a semiconductor device manufacturing apparatus 22 for manufacturing a semiconductor device by using the information relating to the manufacturing condition extracted from the apparatus 11 , and a semiconductor device manufacturing system 10 is built up, and this apparatus 11 comprises an input and output interface 12 for playing the role of interface of input and output processing of information from outside, a controller 13 for controlling the electric characteristic evaluating process of semiconductor device, a discrete lattice point generator 14 for generating discrete lattice points for evaluating the electric characteristics within the structure of the entered semiconductor device, an analyzer 15 for numerically analyzing the physical equations about the physical quantity of the discrete lattice point, a current calculator 16 for calculating the current value of each electrode by using the physical quantity on the discrete lattice point, and an integrator 17 for integrating the carrier generation and extinction speed by each carrier generation and extinction mechanism.
[0033] The electric characteristic evaluating apparatus 11 is connected to an input unit 20 for entering various information such as electric characteristic evaluation information and control information relating to the apparatus 11 , and an output unit 21 for issuing various information such as calculation result of the apparatus 11 and error information. The input unit 20 is realized by keyboard, mouse pointer, light pen, and others, and the output unit 21 is realized by printer, display, etc.
[0034] The input and output interface 12 is preferred to be a graphical user interface allowing the user to process while referring to display information.
[0035] (Electric characteristic evaluating method, semiconductor device manufacturing method)
[0036] [0036]FIG. 2 is a flowchart showing a semiconductor device manufacturing method according to an embodiment of the present invention.
[0037] The semiconductor device manufacturing method according to an embodiment of the present invention is executed in the following steps.
[0038] (1) To enter impurity concentration distribution of semiconductor device of which electric characteristics are to be evaluated, its device shape, and bias conditions (=electric characteristic evaluation information) (device structure, bias condition input step S 201 ).
[0039] Herein, the impurity concentration distribution and device shape of semiconductor device may be entered either by using light pen or other input device, or by using the device structure information obtained by process simulation. As the bias condition, for example, in the case of N type MOSFET, supposing the potential of the source electrode and substrate electrode to be the ground, that is, 0 [V], the voltage to be applied to each electrode may be specified so as to apply 2 [V] to the drain electrode and 2 [V] to the gate electrode, or by grounding the potential of the source electrode and substrate electrode, the changing range and changing amount of the voltage applied to at least one electrode may be specified so as to apply 2 [V] to the drain electrode, and change the voltage applied to the gate electrode in a range from 0 [V] to 2 [V] at 0.1 [V] increments.
[0040] (2) The discrete lattice point generator 14 generates a discrete lattice point necessary for solving the physical equation in the entered device shape (discrete lattice point generating step S 202 ).
[0041] (3) The controller 13 sets the bias condition of voltage and others to be applied to each electrode in the semiconductor device according to the entered bias conditions (bias setting step S 203 ).
[0042] (4) The analyzer 15 numerically solves the physical equation about physical quantities such as the potential on the discrete lattice point and electron concentration, in the boundary condition given as bias condition (physical equation analysis step S 204 ). Herein, the analyzer 15 processes same as the conventional device simulator, by linearizing the physical equation by a very small changing amount, and solving the nonlinear simultaneous equations by using the iteration method.
[0043] (5) The current calculator 16 calculates the current value of each electrode by using physical quantities such as the potential on the discrete lattice point and electron concentration (current calculating step S 205 ).
[0044] (6) The integrator 17 integrates by volume the carrier generation and extinction speed due to each carrier generation and extinction mechanism in the semiconductor region (volume integral value calculating step S 206 ).
[0045] The volume integral value calculating step is described below.
[0046] In the electric characteristic evaluating method of the embodiment of the present invention, different from the prior art, the solving step of physical equation in the given bias condition is followed by a step of volume integration of carrier generation and extinction speed due to each carrier generation and extinction mechanism in the semiconductor region, and by this process, the leak current component due to each carrier generation and extinction mechanism can be evaluated separately.
[0047] Specifically, the volume integral value is extracted in the following steps.
[0048] Generally, in the device simulation, the current preservation formula as shown in FIG. 7A is solved. Herein, n, t, q, Jn, and GRn respectively denote the electron concentration, time, prime charge, electron current density vector, and electron generation and extinction speed, and the polarity sign of electron generation and extinction speed GRn is positive in carrier generation, and negative in extinction. A similar current preservation formula exists for holes, but description is omitted herein.
[0049] The leak current of semiconductor device is originated in the term of generation and extinction speed GRn at the right side of FIG. 7A, and the generation and extinction speed GRn can be expressed by the sum of generation and extinction speeds due to plural generation and extinction mechanisms as shown in FIG. 7B. Herein, GRSRHn is the electron generation and extinction speed due to SRH process, GRIIN is the electron generation and extinction speed due to impact ionization, and GRBBTn is the electron generation and extinction speed due to inter-band tunneling. Only three types of generation and extinction mechanism are assumed herein, but this is only an example, and other generation and extinction mechanisms are also taken into consideration.
[0050] Each generation and extinction speed at the right side in FIG. 7B is expressed by the function of electron concentration or the like, and is taken into the device simulator, and by numerically solving the physical equations, the generation and extinction speed on the discrete lattice point is extracted in each generation and extinction mechanism.
[0051] It is a feature of the electric characteristic evaluating process of the invention that the generation and extinction speed thus extracted is integrated by volume in the semiconductor in every generation and extinction mechanism, and issued, and this process is expressed in formulas as shown in FIGS. 7C to 7 E. The volume integral value may be issued directly, but may be also issued as the product of each value multiplied by prime charge q. That is, the values in the formulas shown in FIGS. 7F to 7 H may be calculated and issued, and in this case the output values are approximate values of the leak current components given by each generation and extinction mechanism. Herein, the reason why approximate values of leak current components are given by each generation and extinction mechanism in FIGS. 7F to 7 H is, physically explaining, the carrier extinction speed in the semiconductor device in a state where leak current is a problem is greater than the carrier generation speed, and therefore the carrier generated by the carrier generation mechanism almost completely flows into the electrode without rebonding, so as to be observed as leak current.
[0052] When the carrier generation and extinction speed is in the dimension of length −3 time −1 , the volume integral value is calculated as described above, but in the case of the carrier generation and extinction mechanism of which speed is in the dimension of length −2 time −1 , such as the carrier generation and extinction mechanism due to SRH process at the interface of semiconductor and insulator, the volume integrated value by the semiconductor is not calculated and issued, but the surface integrated value by the interface is calculated and issued, and similarly in the case of the carrier generation and extinction mechanism having the dimension of length −1 time −1 , the line integrated value is calculated and issued. In the case of carrier generation and extinction mechanism having other dimension, evidently, similar processing is required, but its explanation is omitted.
[0053] In the embodiment, meanwhile, after calculating the current value in each electrode, the volume integral value is extracted, but it is the same if the steps are in reverse sequence.
[0054] (7) The controller 13 issues the current value and volume integral value to the output unit 21 (output processing step S 207 ).
[0055] (8) The controller 13 judges whether or not to evaluated by other bias condition (judging step S 208 ), and when judging by other bias condition as a result of judging, the process goes to bias setting step 203 , and if not evaluating, the process goes to manufacturing condition determining step S 209 .
[0056] (9) On the basis of output of the electric characteristic of the semiconductor device, the manufacturing conditions such as the impurity ion implantation condition and annealing condition for manufacturing the semiconductor device having desired electric characteristics are determined (manufacturing condition determining step S 209 ).
[0057] (10) The semiconductor device manufacturing device 22 executes the semiconductor manufacturing process such as impurity ion implanting process and annealing process on the basis of the determined manufacturing parameters, and manufactures a semiconductor device (semiconductor device manufacturing step S 210 ).
[0058] The electric characteristic evaluating apparatus according to the embodiment of the present invention has an appearance, for example, as shown in FIG. 3. That is, the electric characteristic evaluating apparatus according to the embodiment of the present invention is composed by incorporating components of the electric characteristic evaluating apparatus 11 in a computer system 30 . The computer system 30 comprises a floppy disk drive 32 , and an optical disk driver 34 . A floppy disk 33 is inserted into the floppy disk drive 32 , and an optical disk 36 is inserted into the optical disk driver 34 , and by specified reading operation, the electric characteristic evaluating programs stored in these recording media can be installed in the system. Further, by connecting a specified drive device, for example, by using a ROM 37 playing the role of memory device and a cartridge 38 playing the role of magnetic tape device, it is possible to execute installation or reading or writing of data. Moreover, the user can enter various data relating to the electric characteristic evaluating process by means of keyboard 35 , and know the results of calculation of electric characteristics through the display 31 .
[0059] The electric characteristic evaluating method according to the embodiment of the present invention may be programmed and saved in a computer-readable recording medium. When evaluating the electric characteristic, this recording medium is read into the computer system, and the program is stored in the memory of the computer system, and by executing the electric characteristic evaluating program by the operation unit, the electric characteristic evaluating method of the invention can be realized. The recording medium to be used herein includes, for example, semiconductor memory, magnetic disk, optical disk, magnetooptical disk, magnetic tape, and other computer-readable medium for recording program.
[0060] Thus, the present invention should be understood sufficiently to include various embodiments not described herein. Therefore, the invention should be limited only by the specific matters relating to the claims evident and reasonable from the disclosure herein.
[0061] Finally, results of experiments for evaluating the leak current by using the electric characteristic methods of the prior art and the invention are unveiled below.
Experiment 1
[0062] Experiment 1 was conducted on the silicon N type MOSFET having a device structure as shown in FIG. 4.
[0063] As the carrier generation and extinction mechanism, the SRH process, impact ionization, and inter-band tunneling were assumed, and as the bias condition, 0 [V] was applied to the source electrode and substrate electrode, 1 [V] to the gate electrode, and 2 [V] to the drain electrode.
[0064] First of all, results of evaluation by employing the prior art are shown in FIG. 5A.
[0065] As known from FIG. 5A, in the case of this semiconductor device, in the set bias condition, the inter-band tunneling occupies the majority of leak current, and the leak current due to inter-band tunneling is known to be 9.45×10−14 A. The reason why the current value is slightly different between “BBT only” and “all” is that impact ionization is induced by leak current due to inter-band tunneling in the case of “all”, but such effect is ignored in the case of “BBT only”. On the other hand, in the case of “II only”, there is no leak current due to inter-band tunneling inducing impact ionization, and hence the calculation result of leak current is also different from the case of “all”. Also due to the difference between the current of “all” and “BBT only”, it is estimated that leak current of about 1.7×10−15 A is induced because impact ionization occurs due to leak current by inter-band tunneling.
[0066] On the other hand, in the case of evaluation by using the prior art, although the simulation of “no GR” can be omitted, it is necessary to execute simulation four times, that is, “SRH only”, “II only”, “BBT only”, and “all”, and the leak current due to impact ionization caused by leak current due to inter-band tunneling can be estimated only from plural calculation results.
[0067] Results of evaluation by using the electric characteristic evaluation of the invention are shown at the left side in FIG. 5B.
[0068] As known from the left side in FIG. 5B, it is known that the current value itself is exactly same as in the case of “all” in the prior art.
[0069] The right side of FIG. 5B shows the product of the volume integral value in the silicon substrate of the electron generation and extinction speed specific to the invention multiplied by prime charge q.
[0070] As known from the right side in FIG. 5B, although the leak current component due to SRH process is small, the leak current due to impact ionization is 1.68×10−15 A and the leak current due to inter-band tunneling is 9.45×10−14 A. This result nearly coincides with the result obtained by four times of execution of device simulation in the prior art.
[0071] That is, according to the electric characteristic evaluating method of the present invention, only by simulating once, the contribution of each generation and extinction mechanism to the leak current can be evaluated at high precision. The time required for volume integration of each carrier generation and extinction speed is as short as ignorable in comparison with the entire processing time, and the evaluation by the conventional devices simulation requiring four times of simulation can be realized by one execution according to the electric characteristic evaluating method of the invention, and hence the time required for evaluation is ¼, and the efficiency of evaluation of leak current is significantly improved.
Experiment 2
[0072] In experiment 2, using the silicon N type MOSFET having the same device structure as in experiment 1, the leak current was extracted in different bias condition, that is, 0 [V] was applied to the source electrode and substrate electrode, 2 [V] to the gate electrode, and 2 [V] to the drain electrode.
[0073] Evaluation results by the prior art are shown in FIG. 6A.
[0074] As clear from FIG. 6A, in the case of this device, according to this bias condition, the impact ionization occupies almost all leak current, and there is practically no leak current due to SRH process or inter-band tunneling. Thus, by employing the conventional device simulation, although the simulation of “no GR” can be omitted, it is necessary to execute simulation four times, that is, “SRH only”, “II only”, “BBT only”, and “all”.
[0075] Results of calculation of current value by using the electric characteristic evaluating method of the invention are shown at the left side in FIG. 6B.
[0076] The current value itself is same as in the case of “all” in the case of using the conventional device simulation.
[0077] The right side of FIG. 6B shows the product of the volume integral value in the silicon substrate of the electron generation and extinction speed specific to the invention multiplied by prime charge q.
[0078] As known from the right side in FIG. 6B, although the leak current component due to SRH process and inter-band tunneling is as small as ignorable, the leak current due to impact ionization is 4.33×10−8 A. This result nearly coincides with the result obtained by four times of execution of device simulation in the prior art. That is, according to the electric characteristic evaluating method of the invention, only by simulating once, the contribution of each generation and extinction mechanism to the leak current can be evaluated.
OTHER EMBODIENTS
[0079] Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without depending from the scope thereof. | The present invention quantitatively estimates how much of each carrier generation and extinction mechanism is contributed to the leak current by a single simulation. Thus, according to the present invention, the time required for evaluating the electric characteristics can be substantially curtailed, and the term and expenses of manufacturing a semiconductor device can be curtailed. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to cryogenic energy storage systems, and particularly to methods for the efficient balancing of the liquefaction process with the integrated use of cold recycle from an external source such as a thermal energy store.
BACKGROUND OF THE INVENTION
[0002] Electricity transmission and distribution networks (or grids) must balance the generation of electricity with the demand from consumers. This is normally achieved by modulating the generation side (supply side) by turning power stations on and off, and running some at reduced load. As most existing thermal and nuclear power stations are most efficient when run continuously at full load, there is an efficiency penalty in balancing the supply side in this way. The expected introduction of significant intermittent renewable generation capacity, such as wind turbines and solar collectors, to the networks will further complicate the balancing of the grids, by creating uncertainty in the availability of parts of the generation fleet. A means of storing energy during periods of low demand for later use during periods of high demand, or during low output from intermittent generators, would be of major benefit in balancing the grid and providing security of supply.
[0003] Power storage devices have three phases of operation: charge, store and discharge. Power storage devices generate power (discharge) on a highly intermittent basis when there is a shortage of generating capacity on the transmission and distribution network. This can be signalled to the storage device operator by a high price for electricity in the local power market or by a request from the organisation responsible for the operating of the network for additional capacity. In some countries, such as the United Kingdom, the network operator enters into contracts for the supply of back-up reserves to the network with operators of power plants with rapid start capability. Such contracts can cover months or even years, but typically the time the power provider will be operating (generating power) is very short. In addition, a storage device can provide an additional service in providing additional loads at times of oversupply of power to the grid from intermittent renewable generators. Wind speeds are often high overnight when demand is low. The network operator must either arrange for additional demand on the network to utilise the excess supply, through low energy price signals or specific contracts with consumers, or constrain the supply of power from other stations or the wind farms. In some cases, especially in markets where wind generators are subsidised, the network operator will have to pay the wind farm operators to ‘turn off’ the wind farm. A storage device offers the network operator a useful additional load that can be used to balance the grid in times of excess supply.
[0004] For a storage device to be commercially viable the following factors are important: capital cost per MW (power capacity), MWh (energy capacity), round trip cycle efficiency and lifetime with respect to the number of charge and discharge cycles that can be expected from the initial investment. For widespread utility scale applications it is also important that the storage device is geographically unconstrained—it can be built anywhere, in particular next to a point of high demand or next to a source of intermittency or a bottleneck in the transmission and distribution network.
[0005] One such storage device technology is the storage of energy using cryogen such as liquid air or nitrogen (Cryogenic Energy Storage (CES)) which offers a number of advantages in the market place. Broadly speaking a CES system would, in the charge phase, utilise low cost or surplus electricity, at periods of low demand or excess supply from intermittent renewable generators, to liquefy a working fluid such as air or nitrogen. This is then stored as a cryogenic fluid in a storage tank, and subsequently released to drive a turbine, producing electricity during the discharge or power recovery phase, at periods of high demand or insufficient supply from intermittent renewable generators.
[0006] Cryogenic Energy Storage (CES) Systems have several advantages over other technologies in the market place, one of which is their founding on proven mature processes. Means to liquefy air, necessary in the charging phase, have existed for more than a century; early systems utilised a simple Linde cycle in which ambient air is compressed to a pressure above critical 38 bar), and progressively cooled to a low temperature before experiencing an isenthalpic expansion through an expansion device such as a Joule-Thomson valve to produce liquid. By pressurising the air above the critical threshold, the air develops unique characteristics and the potential for producing large amounts of liquid during expansion. The liquid is drained off and the remaining fraction of cold gaseous air is used to cool the incoming warm process stream. The amount of liquid produced is governed by the required amount of cold vapour and inevitably results in a low specific yield.
[0007] An evolution of this process is the Claude cycle (for which the current state of the art is shown in FIG. 4 ); the process is broadly the same as the Linde cycle however one or more streams 36 , 39 are separated from the main process stream 31 where they are expanded adiabatically through turbines 3 , 4 , resulting in a lower temperature for a given expansion ratio than an isenthalpic process and hence efficient cooling. The air expanded through turbines 3 , 4 then rejoins the returning stream 34 and aids the cooling of the high pressure stream 31 via heat exchanger 100 . Similar to the Linde cycle the bulk of liquid is formed via expansion through an expansion device such as a Joule-Thomson valve 1 . The main improvement with the Claude process is that power produced by the expansion turbines 3 , 4 directly or indirectly reduces the overall power consumption, resulting in greater energy efficiency.
[0008] The most efficient modern air liquefaction processes typically use a two turbine Claude design, and at commercial scale can typically achieve an optimum specific work figure of around 0.4 kWh/kg. Although highly efficient this would not enable a CES system to achieve a market entry Round Trip Efficiency figure of 50%, without significant reductions in specific work.
[0009] In order to achieve greater efficiencies the liquefaction process within a fully integrated CES system, such as the one disclosed in W02007-096656A1, utilises cold energy captured in the evaporation of the cryogen during the power recovery phase. This is stored by means of an integrated thermal store, such as the one detailed in GB 1115336.8, and then used during the charging phase to provide additional cooling to the main process stream in the liquefaction process. The effective use of the cold recovery stream is a prerequisite to achieving an efficient cryogenic energy storage system.
[0010] The necessary change in enthalpy that an arbitrary high pressure process stream must undergo to reach the required temperature to maximise liquid production when expanded through an expansion device such as a Joule-Thomson valve is shown in FIG. 1 . A typical ideal cooling stream must similarly undergo an enthalpy change throughout the process as shown by the profile in FIG. 2 , marked ‘No Cold Recycle’. The second profile in FIG. 2 demonstrates the dramatic change in required cooling (i.e. relative change of enthalpy) when large quantities of cold recycle are introduced into the system, marked ‘Cold Recycle’. FIG. 2 shows quantities of cold recycle in the region of 250 kJ/kg (defined as cooling enthalpy per kg of liquid product delivered), which is consistent with levels of cold recycle used in a fully integrated cryogenic energy system such as the one disclosed in W02007-096656A1. As is evident from FIG. 2 , the addition of the cold recycle completely satisfies the cooling requirements in the higher temperature end of the process.
[0011] This presents a problem with current state of the art liquefaction processes which are designed to be used with more progressive thermal energy profiles, and are much more effectively handled by a single cooling stream running the extent of the heat exchanger. As can be seen from FIG. 3 the effective cooling stream produced by current state of the art processes (indicated by profile marked ‘state of the art’), such as the Claude cycle shown in FIG. 4 , is extremely linear in comparison to the required profile in a system using large quantities of cold recycle (indicated by profile marked ‘Ideal Profile’), and a very poor match. To meet the acute cooling demand at the lower temperature end, a typical state of the art process must expand a similar quantity of air through the cold turbine as a system without cold recycle. This results in poor efficiencies and heat transfer requirements above the maximum design level of the device within the process heat exchangers.
[0012] The present inventors have identified that there is a need for a system that can provide focused non-progressive cooling to concentrated areas of the process, in particular at the lower temperature end of the process.
SUMMARY OF THE INVENTION
[0013] A first aspect of the present invention addresses these needs by providing, in a first embodiment, a cryogenic liquefaction device comprising:
a heat exchanger; a first phase separator; a first expansion device; a first expansion turbine; a second expansion turbine; a cold recovery circuit including a heat transfer fluid; and an arrangement of conduits, wherein:
the operating inlet pressures of the first and second expansion turbines are different from one another; and the arrangement of conduits is arranged such that:
a first portion of a pressurised stream of gas is directed through the heat exchanger, the first expansion device and the first phase separator; a second portion of the pressurised stream of gas is directed through the first expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas, and then through the second expansion turbine, and the heat transfer fluid is directed through the heat exchanger.
[0026] In the context of the present invention, the phrase “a counter-flow direction” is used to mean that the second portion of the pressurised stream of gas flows through the heat exchanger in an opposite direction to the first portion of the pressurised stream of gas, for at least a part of its path through the heat exchanger. The first and second portions of the pressurised stream of gas may enter the heat exchanger at opposite ends, i.e. so that the temperature difference between the entry points is maximised. Alternatively, the first and or second portion of the pressurised stream of gas may enter the heat exchanger at a point between the ends of the heat exchanger, but flow through the heat exchanger in an opposite direction to the other of the first and second portion of the pressurised stream of gas, for at least a part of its path through the heat exchanger.
[0027] The cold recovery circuit comprises a thermal energy storage device, a means for circulating the heat transfer fluid (HTF), and an arrangement of conduits arranged to direct the HTF through the thermal energy storage device and into the heat exchanger. An exemplary cold recovery circuit is described in detail in GB 1115336.8. The HTF may comprise a gas or a liquid, at high or low pressure.
[0028] The configuration of the present invention is such that the second portion of the cooled process stream can be partially expanded through the first turbine to provide a high pressure cooling stream local to the entry point of the cold recovery stream of the cold recovery circuit. The stream can then be further expanded through the second turbine to provide significant additional cooling to the lower section of the process.
[0029] The present invention offers increased work output from the expansion turbines as a result of the reheating of the expanded stream, whilst also providing cooling between expansion turbines.
[0030] The pressurised stream of gas may consist of gaseous air. Alternatively, the pressurised stream of gas may consist of gaseous nitrogen. The pressurised stream of gas may be input into the cryogenic liquefaction device at a pressure greater than or equal to the critical pressure which, for gaseous air is 38 bar and for gaseous nitrogen is 34 bar.
[0031] After the pressurised stream of gas is split into two portions, the first portion of the pressurised stream of gas and the second portion of the pressurised stream of gas may be at the same pressure. Alternatively, the first portion of the pressurised stream of gas and the second portion of the pressurised stream of gas may be at different pressures. In particular, the first portion may be above the critical pressure, and the second portion may be below the critical pressure, or vice versa.
[0032] The cryogenic liquefaction device may comprise more than two expansion turbines, with turbines in both parallel and series.
[0033] The cryogenic liquefaction device may further comprise a third expansion turbine, wherein the operating inlet pressure of the third expansion turbine is different to at least one of the first and second expansion turbines.
[0034] The arrangement of conduits may be such that the third expansion turbine is in parallel with at least one of the first and second turbines such that at least a portion of the second portion of the pressurised stream of process gas is directed through the third turbine.
[0035] The arrangement of conduits may be such that the third expansion turbine is in series with at least one of the first and second turbines such that at least a portion of the second portion of the pressurised stream of process gas is directed through the third turbine.
[0036] The cryogenic liquefaction device may further comprise a refrigerant circuit which is connected to the output of the second expansion turbine via the arrangement of conduits.
[0037] The cryogenic liquefaction device may further comprise a second arrangement of conduits that directs a second heat transfer fluid through a closed cycle refrigeration circuit and through a localised area of the heat exchanger. The second heat transfer fluid within the refrigerant circuit may comprise a gas or a liquid, at high or low pressure.
[0038] The cryogenic liquefaction device may further comprise a fourth expansion turbine, wherein the arrangement of conduits is arranged such that:
[0039] a third portion of the pressurised stream of gas is directed through the fourth expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas.
[0040] The cryogenic liquefaction device may further comprise a fifth expansion turbine, wherein the arrangement of conduits is arranged such that:
[0041] the third portion of the pressurised stream of gas is directed through the fifth expansion turbine after passing through the fourth expansion turbine and the heat exchanger.
[0042] The cryogenic liquefaction device may further comprise a second phase separator and a second expansion device, wherein the arrangement of conduits is arranged such that at least a portion of the second portion of the pressurised stream of gas is directed through the second expansion device and the second phase separator after having passed through the first expansion turbine.
[0043] The or each expansion device may comprise a Joule-Thomson valve, another pressure reducing valve, an expansion turbine or another work extracting device.
[0044] The cryogenic liquefaction device may further comprise a first compressor, wherein the arrangement of conduits is arranged such that at least a portion of the second portion of the pressurised stream of gas is directed through the first compressor before passing through the first expansion turbine.
[0045] The cryogenic liquefaction device may further comprise a second compressor, wherein the arrangement of conduits is arranged such that the first portion of the pressurised stream of gas is directed through the second compressor before passing through the heat exchanger.
[0046] The cryogenic liquefaction device may further comprise a cooler, wherein the arrangement of conduits is arranged such that the first portion of the pressurised stream of gas is directed through the cooler after passing through the second compressor and before passing through the heat exchanger.
[0047] The cryogenic liquefaction device may further comprise a feed stream compressor adapted to output the pressurized stream of gas, wherein the arrangement of conduits is arranged firstly such that a feed stream is directed to the input of the feed stream compressor; and secondly such that the output stream from the first phase separator joins the feed stream after passing through the heat exchanger.
[0048] The arrangement of conduits may be arranged such that the pressurized stream of gas output from the feed stream compressor is directed to a heat storage device before passing through the heat exchanger.
[0049] The arrangement of conduits may be arranged such that the pressurized stream of gas output from the heat storage device is directed to a heat rejection device before passing through the heat exchanger.
[0050] The first aspect of the present invention further provides a method for thermally balancing a liquefaction process with the use of cold recycle from an external thermal energy source comprising:
[0051] directing a first portion of a pressurised stream of gas through a heat exchanger, a first expansion device, and a first phase separator;
[0052] directing a second portion of a pressurised stream of gas through a first expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas, and then through a second expansion turbine; and
[0053] directing a heat transfer fluid through a cold recovery circuit and the heat exchanger; wherein:
the operating inlet pressures of the first and second expansion turbines are different from one another.
[0055] Any of the optional features recited above in connection with the cryogenic liquefaction device may also be incorporated into the method of the first aspect of the present invention.
[0000] A second aspect of the present invention addresses these needs by providing, in a first embodiment, a cryogenic liquefaction device comprising: a heat exchanger;
a first phase separator; a first expansion device; a first expansion turbine; a first compressor;
a cold recovery circuit including a heat transfer fluid; and an arrangement of conduits, arranged such that:
a first portion of a pressurised stream of gas is directed through the heat exchanger, the first expansion device and the first phase separator; a second portion of the pressurised stream of gas is directed through the first expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas, and then through the first compressor, and the heat transfer fluid is directed through the heat exchanger.
[0064] The arrangement of conduits may be arranged such that the output stream of the first compressor joins the pressurised stream of gas.
[0065] The arrangement of conduits may be arranged such that the output stream of the first compressor is directed into the heat exchanger before it joins the pressurised stream of gas. Alternatively, the arrangement of conduits may be arranged such that the output stream of the first compressor joins the pressurised stream of gas before it is directed into the heat exchanger.
[0066] The first compressor may be either a single stage or a multistage compressor.
[0067] The second aspect of the present invention further provides a method for balancing a liquefaction process with the use of cold recycle from an external thermal energy source comprising:
[0068] directing a first portion of a pressurised stream of gas through a heat exchanger, a first expansion device, and a first phase separator;
[0069] directing a second portion of a pressurised stream of gas through a first expansion turbine, then through the heat exchanger in a counter-flow direction to the first portion of the pressurised stream of gas, and then through a first compressor; and
[0070] directing a heat transfer fluid through a cold recovery circuit and the heat exchanger.
[0071] Any of the optional features recited above in connection with the cryogenic liquefaction device may also be incorporated into the method of the second aspect of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] Embodiments of the present invention will now be described with reference to the figures in which:
[0073] FIG. 1 shows a profile of the relative change in total enthalpy which a process gas undergoes during the cooling process (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
[0074] FIG. 2 shows profiles of the relative change in total enthalpy which the cooling streams must undergo during the cooling process for systems with and without the use of large quantities of cold recycle (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
[0075] FIG. 3 shows profiles of the relative change in total enthalpy which the cooling streams must undergo during the cooling process for ‘ideal’, ‘state of art’ and ‘present invention’ systems with the use of large quantities of cold recycle (Relative Change of Total Enthalpy vs Cooled Stream Temperature);
[0076] FIG. 4 shows a typical state of the art air liquefaction plant arrangement using the Claude cycle;
[0077] FIG. 5 shows a schematic of a cryogenic energy storage system liquefaction process according to a first embodiment of the first aspect of the present invention;
[0078] FIG. 6 shows a second embodiment of the first aspect of the present invention;
[0079] FIG. 7 shows a third embodiment of the first aspect of the present invention;
[0080] FIG. 8 shows a fourth embodiment of the first aspect of the present invention;
[0081] FIG. 9 shows a fifth embodiment of the first aspect of the present invention;
[0082] FIG. 10 shows a sixth embodiment of the first aspect of the present invention;
[0083] FIG. 11 shows a seventh embodiment of the first aspect of the present invention;
[0084] FIG. 12 shows a variation of the second embodiment of the present invention;
[0085] FIG. 13 shows a variation of the seventh embodiment of the present invention;
[0086] FIG. 14 shows an eighth embodiment of the present invention;
[0087] FIG. 15 shows a variation of the first embodiment of the present invention;
[0088] FIG. 16 shows another variation of the first embodiment of the present invention;
[0089] FIG. 17 shows yet another variation of the first embodiment of the present invention; and
[0090] FIG. 18 shows a first embodiment of the second aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0091] The first simplified embodiment of the present invention is shown in FIG. 5 . The system in FIG. 5 is similar to that of the state of the art shown in FIG. 4 in that the main process stream 31 is cooled via cold expanded air from turbines and expanded through an expansion device such as a Joule-Thomson Valve 1 to produce liquid, however the warm turbine 3 of FIG. 4 is replaced by a second cold turbine 6 aligned in series with the first cold turbine 5 .
[0092] In the first embodiment of the present invention shown in FIG. 5 , the process gas (in the preferred embodiment air) is compressed to high pressure, of at least the critical pressure (which for air is 38 bar, more preferably >45 bar), and at ambient temperature (≈298K) enters the cryogenic liquefaction device at inlet 31 , from where it is directed through a heat exchanger 100 and cooled progressively by cold low pressure process gas, before returning through the heat exchanger 100 via passage 41 , 42 . Also passing through the heat exchanger 100 is a cold recovery stream 30 , 50 of a cold recovery circuit of the cryogenic liquefaction device. The cold recovery circuit comprises: a thermal energy storage device (not shown); a means for circulating a heat transfer fluid through the cold recovery circuit (not shown); and an arrangement of conduits arranged to direct the heat transfer fluid through the thermal energy storage device and the heat exchanger 100 . An exemplary cold recovery circuit is described in detail in GB 1115336.8
[0093] A proportion of the high pressure process gas input into the heat exchanger at 31 , and now at a temperature of between 150-170K (in the preferred case 165K), is separated from the main flow 31 , via passage 39 , and is partially expanded to between 5 and 20 bar (more typically 10-14 bar), using expansion turbine 5 , before passing through passage 40 , 43 of the heat exchanger 100 , where cold thermal energy is transferred to the high pressure gas in stream 35 . This feature of the present invention provides more effective cooling than the arrangement of FIG. 4 as a result of the higher pressure cooling stream 40 , 43 around the entry point of the cold recovery stream 30 , better matching the resultant cooling demand (as shown in FIG. 3 ) than conventional layouts, where the warm turbine 3 (of FIG. 4 ) provides cooling at higher temperatures which are not required where cold recycle is available.
[0094] The partially expanded gas stream in passage 40 , 43 is heated to a temperature between 120-140K (in the preferred case 125K), as a result of the thermal transfer in passage 40 , 43 through heat exchanger 100 , and is further expanded through turbine 6 , to between ambient and 6 bar where it travels through passage 44 and enters the phase separator vessel 2 . The gas fractions of streams 32 and 44 are combined to form output stream 34 , which travels through passage 41 , 42 through heat exchanger 100 which provides additional cooling to the high pressure process stream 35 . An additional advantage of the present invention is that the typical composition of the cold process stream in stream 44 is a mixture of liquid and gaseous air. The liquid fraction from the final expansion is collected within the phase separator 2 and output via passage 33 .
[0095] The numbered points in FIG. 5 indicate positions in the system at which typical absolute pressures, temperatures and mass flows are as follows:
[0000]
Temperature
Pressure
Mass Flow
Point
(K)
(bar)
(kg/hr)
31
298
45
16651
35
165.5
45
7160
38
101
45
7160
32
91.23
4
7160
33
91.23
4
6249
34
91.23
4
911
39
165.5
45
9491
40
113
11.23
9491
43
125.5
11.23
9491
44
95.91
4
9491
41
95.49
4
10402
42
295.3
4
10402
30
115
1.2
8280
50
295.3
1.2
8280
[0096] A second embodiment of the current invention is shown in FIG. 6 (where like reference numerals refer to the same components as in FIG. 5 ), wherein the proportion of air separated from the main stream 31 via passage 39 is carried out later in the process and therefore at a lower temperature (between 130-170K). As a result the subsequent temperature of the cold gas after partial expansion in turbine 5 , is sufficient to provide a high pressure cooling stream for the bottom end of the process stream 35 via passage 40 , 43 , after which it is expanded again through the second turbine 6 to provide additional focussed cooling in stream 34 .
[0097] A third embodiment of the present invention is shown in FIG. 7 (where like reference numerals refer to the same components as in FIG. 5 ) wherein a third expansion turbine 7 is provided in parallel with the second turbine 6 which remains in series with turbine 5 . Similar to the second embodiment shown in FIG. 6 , a portion 39 of the cold high pressure stream 31 is partially expanded by turbine 5 to provide a high pressure cooling stream 40 at the lower end of the heat exchanger only, before it is split again into two streams 43 , 45 and expanded through the two further turbines 6 and 7 in parallel. The outlet from turbine 7 is introduced typically into the phase separator 2 via passage 80 . In some embodiments where the cold recycle temperatures are low the outlet from turbine 7 may be introduced higher up the heat exchanger 100 via passage 46 .
[0098] FIG. 8 (where like reference numerals refer to the same components as in FIG. 7 ) details a fourth embodiment of the present invention wherein, similar to the system shown in FIG. 7 , a third expansion turbine 7 is added and placed in parallel to the second expansion turbine 6 which remains in series with the first expansion turbine 5 . The expansion ratios of the second 6 and third 7 turbines are different from each other, the second expanding from around 8 bar to 4.5 bar, and the third expanding from around 8 bar to near ambient. The inventors have realised that by layering multiple cooling streams in parallel as in FIG. 8 , the cooling profile demand, identified in FIG. 3 , can be more closely matched. In some embodiments, where the outlet pressure of turbine 7 is substantially equal to the separator pressure 2 , the outlet of turbine 7 is introduced to the phase separator 2 via passage 80 where liquid formed in the outlet of turbine 7 is collected.
[0099] A further embodiment is shown in FIG. 9 (where like reference numerals refer to the same components as in FIG. 8 ). This embodiment is the same as that of FIG. 8 except that the exiting gases travelling through stream 48 from the second expansion turbine 6 are removed from the process heat exchanger 100 before reaching the top. The cold gases in stream 48 are further compressed, by compressor 8 , and the resultant stream 49 is cooled by a closed cycle refrigeration circuit 10 before exiting the circuit 10 as stream 51 and mixing with the high pressure process stream 31 . In certain embodiments there is the potential for a proportion of liquid to be formed in stream 46 from the cold gas on exiting the third turbine 7 , whereby the stream would be directed via passage 80 to enter the phase separator 2 , instead of being directed straight through the heat exchanger 100 via passageway 46 , 47 .
[0100] In a further embodiment (not shown but otherwise the same as FIG. 9 ), the outlet of turbine 7 may be expanded to near ambient so that this process stream can be used to drive a low pressure high grade cold store, such as that detailed in GB1115336.8.
[0101] The embodiment shown in FIG. 10 (where like reference numerals refer to the same components as in FIG. 5 ) is the same as that of FIG. 5 except for the addition of a closed cycle refrigeration circuit 101 to provide a local potentially high pressure cooling stream 60 to better match the cooling demand. The closed cycle refrigeration circuit 101 includes compressor 102 , cooler 103 and expansion turbine 104 .
[0102] FIG. 11 shows a further embodiment of the present invention (where like reference numerals refer to the same components as in FIG. 5 ) wherein a warm turbine 14 and cold turbine 5 partially expand portions 60 , 39 of the cold high pressure stream 31 . Streams 60 and 39 are at different temperatures and are expanded to different pressures by turbines 14 and 5 to provide streams 61 and 40 , respectively. Gas in streams 61 and 40 provides focussed cooling to the high pressure stream at points 35 and 69 , before separately being expanded to between 0 and 6 bar, using further turbines 16 and 6 to provide streams 63 and 44 which are directed through heat exchanger 100 .
[0103] A variation to the second embodiment is shown in FIG. 12 (where like reference numerals refer to the same components as in FIG. 6 ) wherein the addition of a second phase separator 18 and pressure reducing valve 19 enable the removal of additional liquid produced in stream 40 . In some embodiments the outlet pressure of turbine 6 is equal to the separator pressure 2 and the outlet of turbine 6 is introduced to the phase separator via passage 80 where liquid formed in the outlet to turbine 7 is collected.
[0104] A further component (not shown), which can be included in any of the previous embodiments is a closed loop refrigeration cycle (similar to cycle 101 shown in FIG. 10 ), that utilises a different working fluid to provide additional cooling at a specific section of the system where the cooling requirements are particularly high, in particular between 140 and 120K. The different working fluid may comprise a refrigerant such as methane.
[0105] A further arrangement, which can be applied to any of the previous embodiments where the high pressure stream is divided into two streams of different pressure, includes providing the first stream (that is cooled and then transferred to the expansion device) at a pressure above the critical pressure to maximise liquid production. The second high pressure stream is at a different pressure (typically above the first stream pressure) and is cooled and transferred to the two or more expansion turbines to provide additional cooling to the first stream as described in the previous embodiments.
[0106] In a further embodiment as shown in FIG. 13 (where like reference numerals refer to the same components as in FIG. 5 ) the second stream 58 is compressed by compressor 20 to stream 59 and is then divided into a further two or more streams 63 , 65 . Stream 65 is compressed by compressor 19 and then directed, via a first stream ( 66 ), through two turbines 5 , 6 in series. Stream 63 is expanded through a third turbine 21 . The outlet streams 40 , 44 , 64 of the first, second and third turbines 5 , 6 , 21 provide additional cooling for the first process stream 35 prior to expansion in an expansion device such as a Joule-Thomson valve 1 .
[0107] In a further embodiment, as shown in FIG. 14 (where like reference numerals refer to the same components as in FIG. 5 ) applied to the first embodiment, the cooled gas stream 31 is fed directly from a compressor commonly referred to as a Recycle Air Compressor (RAC) and a stream 58 is split from the cooled gas stream 31 and subsequently boosted to a higher pressure by compressor 19 before being directed through expansion turbines 5 and 6 and heat exchanger 100 . This additional booster component can be incorporated into any of the previous embodiments.
[0108] FIG. 15 (where like reference numerals refer to the same components as in FIG. 14 ) shows a variation of the embodiment of FIG. 16 whereby stream 31 is fed directly from the RAC. Stream 31 is split into two streams 41 and 35 ; stream 41 is directed through heat exchanger 100 , where it is cooled before being directed through expansion turbines 5 and 6 and again heat exchanger 100 , while stream 35 is boosted to a higher pressure by booster 19 before being directed through heat exchanger 100 and an expansion device such as a Joule-Thomson valve 1 .
[0109] FIG. 16 (where like reference numerals refer to the same components as in FIG. 15 ), shows a variation where stream 31 is again fed directly from the RAC and compressed to a pressure lower than the critical pressure (<38 bar). Stream 41 splits from the main cooled stream 31 prior to the remainder of the main cooled stream 35 being boosted and subsequently cooled by boosters 19 and 20 , and coolers 10 and 22 . The sub critical pressure stream 41 is cooled via heat exchanger 100 before being partially expanded, to between 5 and 20 bar, but more typically 10-14 bar, through expansion turbine 5 before passing through passage 40 , 43 , of the heat exchanger 100 , where cold thermal energy is transferred to the high pressure gas in stream in passage 73 , 38 , and being further expanded by expansion turbine 6 . The additional components arranged in stream 35 can also be incorporated in any of the previous embodiments.
[0110] In the final embodiment, as shown in FIG. 17 (where like reference numerals refer to the same components as in FIG. 15 ) shows a variation where output stream of the first phase separator 2 becomes low pressure return vapour 42 , having passed through the heat exchanger 100 , and merges with a feed stream 401 to form stream 402 . The pressure of stream 402 can be between 3 barA and 15 barA, more typically 8 barA. Stream 402 is directed to a single stage compressor 400 , which boosts the stream 402 to a higher pressure. The output stream 403 of the single stage compressor 400 therefore has a higher pressure than stream 402 . The higher pressure is at least the critical pressure (which for air is 38 bar, more preferably >45 bar). The temperature of stream 403 can be between 100 deg C and 400 deg C, more typically 270 deg C. Stream 403 is directed to a heat storage device 404 which removes at least some of the heat energy in the stream 403 . The temperature of the output stream 405 of the heat storage device 404 can be between 20 deg C and 100 deg C, more typically 60 deg C. If the temperature of stream 405 is above ambient temperature the heat rejection device 406 may be used to cool the temperature of the stream. When this liquefaction cycle is used as part of a cryogenic energy storage plant it is highly preferable that the heat of compression captured by the heat storage device 404 is used in the power recovery cycle to boost the temperature of the working fluid at the inlet of the expansion turbines.
[0111] FIG. 18 (where like reference numerals refer to the same components as in FIG. 4 ) shows an embodiment of the invention which is a further development of the air liquefaction plant arrangement of FIG. 4 . Here, the cold vapour stream 40 , which is output from the expansion turbine 4 , is directed to the heat exchanger 100 rather than merging with returning stream 34 to form stream 41 as shown in FIG. 4 . The cold vapour stream 40 thus gains heat as it passes through the heat exchanger 100 and exits the heat exchanger as stream 43 . The temperature of stream 43 can be between 0 deg C and −180 deg C, more typically −117 deg C. Stream 43 is directed to a compressor 300 , which boosts the stream 43 to a higher pressure. The compressor 300 can be a multistage compressor or a single stage compressor. The output stream 301 of the compressor 300 is directed back to heat exchanger 100 in one of two arrangements. If the temperature of stream 301 is near ambient temperature then it can be directed to merge with stream 35 outside the heat exchanger 100 . This is shown by stream 302 . Alternatively, if the temperature of stream 301 is below ambient temperature then it can be directed to merge with the stream 35 insider the heat exchanger to form stream 74 . This is shown by stream 303 .
[0112] It will of course be understood that the present invention has been described by way of example, and that modifications of detail can be made within the scope of the invention as defined by the following claims. | Methods and apparatus are disclosed for efficient cooling within air liquefaction processes with integrated use of cold recycle from a thermal energy store. | 5 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/600,159 filed on Aug. 10, 2004 which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
X-ray imaging technology plays a critical and important role in healthcare and biomedical research. X-ray radiography is one of the most important and widely deployed medical diagnostic methods that can be traced back to the invention of x-rays more than 100 years ago. Recently, soft x-ray cryo-microscopy has been demonstrated to offer non-destructive high resolution three dimensional tomographic imaging of single biological cells with a resolution of about 25 nanometers (nm) in two dimensions (2-D) and 60 nm in three dimensions (3-D). Important trace elements in a biological specimen such as a cell or tissue can be mapped with sensitivity better than parts per billion at a spatial resolution of about 100 nm using a synchrotron based x-ray fluorescence microscope.
An additional important application for higher performance zone plate lenses is high throughput laboratory protein crystallography systems. The knowledge of three-dimensional structures of proteins gives insight into their functionality, and can provide key information for rational drug design to treat human diseases. The underlying hypothesis is that if the structure of the active site of a critical enzyme in a metabolic or regulatory pathway is known, the chemical compounds can then be designed to inhibit or affect the behavior of that specific enzyme. Information on the structural design of proteins also facilitates protein engineering to purposely modify the structures of proteins for specific applications. Thus far, structures for about 19,000 proteins have been deposited in the protein data bank, including 3300 entries added in 2001, out of about 100,000 proteins assumed to be manufactured in the human body, and of course protein structures from other organisms are of great scientific, societal, and commercial interest as well.
At present, it is very difficult to predict the proper folded structure for proteins based on their amino acid sequences. X-ray protein crystallography is the single most useful tool to determine macromolecule structures such as proteins, especially for molecular weights above about 30 kD. Currently, a typical laboratory based x-ray protein crystallography facility is expensive to equip, and it takes a day or two to collect diffraction data sufficient to determine a new protein structure once proper crystallization conditions have been found. Considering the possibility that many attempts are often made to obtain data sufficient for structural determination (due to sample quality, etc.), solving structures of all 10,000 proteins will be a great challenge in both facility cost and human effort. The alternative approach is to use synchrotron beamlines for data collection, where the higher flux and brightness of the source, along with its energy tunability for methods like multiple wavelength anomalous dispersion (MAD), means that an entire dataset appropriate for rapid structure determination can be collected in a matter of hours.
More generally, x-ray microscopy is a complementary tool to light and electron microscopes for biomedical and other research. In recent years, increasingly powerful imaging methods have provided more detailed views of cells. Making use of the development of function specific labeling and contrast enhancement techniques, many forms of imaging techniques have been employed to enable researchers to make key discoveries of the working mechanisms of cells and biological systems. The ability to perform function specific imaging using labels, such as green fluorescent protein, quantum dots, and immunogold, provides the means to elucidate the important link between the working mechanism of cells and tissues and molecular machines at the protein, DNA, and macromolecular assembly level. Optical and electron microscopes are essential for many of these important discoveries and have been widely deployed in biomedical research laboratories. However, various limitations exist in the current microscopy techniques. Existing systems can not address the needs of biologists who wish to visualize the organization of organelles inside a single cell, or connections (such as synapses) between two or more cells with high resolution.
Critical to the development and performance of x-ray microscopes are x-ray lenses that image the x-rays from the object of interest onto a detector system such as an optical stage or directly on an electronic detector device. The task of focusing x-rays has occupied physicists for over a century. All three well known optical phenomena (refraction, reflection, and diffraction) have been exploited to produce x-ray lenses with unique advantages and limitations.
The main challenge (but also a unique advantage) when dealing with x-rays is that they interact with matter only very weakly. The difference in the refractive index between vacuum (or air) and solids is less than 10 −5 for 8 keV x-rays even for dense materials like gold. To overcome this, a concept of using many weakly focusing lenses arranged along the optical axis (termed “compound refractive lens”) was proposed about 10 years ago to increase the effective numerical aperture of refractive x-ray lenses. Although significant progress has been made over the years, its performance in terms of numerical aperture and resolution significantly lags behind the currently available reflection and diffraction based x-ray lenses. The numerical aperture achievable using this type of x-ray lenses is fundamentally limited due to photoelectric absorption for low energy x-rays and Compton scattering for high energy x-rays.
Reflection based lenses are capable of obtaining fairly large numerical apertures especially when the reflecting surface is coated with a multilayer with a small period, but their resolution is limited by stringent tolerance requirements in the smoothness and the slope error of the reflecting surface. Furthermore, the field of view of a reflection based lens is typically very small unless a special, axially symmetric optical design such as a Wolter mirror is used, which employs two consecutive reflections off internal surfaces of parabolic and hyperbolic shape. Since it is difficult to achieve 100 nm resolution using a single monolithic reflecting surface under the optimal conditions, no one has been able to produce a reflection based lens with a reasonable field of view and sub-micrometer resolution.
X-ray zone plates are diffraction based lenses and currently offer the best optical performance for high resolution x-ray imaging and home-lab protein crystallography utilizing a microfocus x-ray source. They combine the highest spatial resolution (˜20 nm with soft x-rays) achievable over the whole electromagnetic spectrum and a large field of view that can be up to ⅓ of the zone plate diameter (typically many tens of micrometers).
Currently the best performing zone plate lenses for x-rays in terms of resolution and efficiency are fabricated by means of a deep pattern transfer process based on semiconductor/microelectromechanical system (MEMS) technology. In this process a zone plate pattern is written by electron beam lithography in a very thin layer of high-resolution photoresist. This pattern is transferred by a directional (anisotropic) reactive ion etch into a thick layer of photoresist, which forms the mold for electrochemical plating of a metal. For soft x-rays (<1 keV) zone plates with outermost zone widths as small as 20 nm have been demonstrated. For hard x-rays the zone thickness requirement increases drastically (from 100 nm for soft x-rays to 1600 nm for 10 keV x-rays) making the fabrication of fine outermost zones much more challenging. Current state of the art zone plate fabrication technology is based on a multi-level lithographic process based on microfabrication technology for manufacturing semiconductor devices. The process however is limited in the smallest achievable zone width and especially in obtaining adequate thickness for efficient focusing of multi-keV x-rays.
SUMMARY OF THE INVENTION
While the progress in the fabrication of hard x-ray zone plates has significantly advanced within the last few years, the existing pattern transfer fabrication processes may reach a practical limit very soon. As the polymer structures of the electroplating mold become smaller and smaller in width they loose strength and tend to collapse during the fabrication process. Also the directionality of the reactive ion etch may impose practical limits to the achievable sidewall angle in the resist, limiting the achievable width of features that can be fabricated. From current fabrication data it can be estimated that the practical limit for hard x-ray zone plates using current pattern transfer technology is around 20-30 nm (structure height ≅1 μm).
It has been proposed and demonstrated to use a wire as the substrate and deposit alternating layers of high- and low-Z materials in a controlled way to obtain the correct pitch for a zone plate. In this process the wire is subsequently sliced and polished to obtain a zone plate. It has been found, however, that for these “Sputter-Sliced zone plates” imperfections in the wire and defects during deposition lead to accumulative errors in the fine outermost zones, which are deposited last. Furthermore, it proved very difficult to slice the wire without deforming the delicate zone plate structure. The resulting zone plates therefore fell short of expectations leading to the abandonment of this project.
The present approach to fabricating zone plate lenses is based on controlled thin layer deposition for fabricating structures as small as 2 nanometers (nm) in width, and potentially smaller. The substrate for deposition will take the form of a precision hole, fabricated in a substrate, such as silicon by electron beam lithography and subsequent reactive ion etching. A controlled layer deposition is then used to form the required zone plate structure. A subsequent thinning process is used to produce a zone plate with the required thickness.
The approach can be used to develop a fast x-ray lens that will improve the performance of all the x-ray techniques described above, which are limited by the currently available x-ray lenses. One example is a diffractive zone plate lens with an outermost zone width of about 7 nm and with a thickness optimized for a desired x-ray energy working over a large range of energies. It can thus have a numerical aperture (NA) that is 5-10 times bigger than the NA of x-ray focusing optics currently available. Its figures of merit, such as resolution and throughput, are proportional to NA or NA 2 respectively. It will enable the development of 3-D x-ray microscopy and x-ray elemental mapping with sub-10 nm resolution using synchrotron x-ray sources, and a compact laboratory source-based protein crystallography system with a throughput more than 10 times better than the best commercially available laboratory system at a significantly lower cost.
An x-ray microscope utilizing the disclosed lenses technology can have better than 20 nm spatial resolution for 2-D imaging and 60 nm for 3-D imaging. These values are significantly inferior to those of available electron microscopes but the proposed x-ray microscope is well compensated by its other unique capabilities, such as imaging single cells and relatively large tissue samples in their entirety without cross sectioning and in their natural state without staining, and substantially higher sensitivity for elemental analysis. Furthermore, its resolution may be sufficient for many important applications and it will offer significantly higher throughput in 3-D imaging of single cells and tissues compared to electron microscopy.
In general according to one aspect, the invention features a method for fabricating a zone plate. The method comprises forming a hole in a substrate, depositing successive layers into the hole, and sectioning the successive layers in the hole to form a zone plate lens.
In embodiments, the step of forming the hole comprises forming the hole with vertical sidewalls. However, sloping sidewalls of between 0.5 and 10 degrees can also be fabricated.
Preferably during the layer deposition, the substrate is rotated, such as in a planetary fashion if the deposition process is directional such as in physical vapor deposition. No rotation is necessary if a non-directional deposition process such as chemical vapor deposition or atomic layer deposition is employed.
The sectioning is preferably accomplished by polishing, such as chemical mechanical polishing (CMP), the substrate.
During or after polishing, wafer bonding can be used to ensure that integrity of the zone plate.
In general according to another aspect, the invention features a zone plate lens made by a method comprising forming a hole in a substrate, depositing successive layers into the hole, and sectioning the successive layers in the hole to form the zone plate lens.
The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
FIGS. 1A and 1B are schematic representations of a zone plate lens illustrating its key parameters;
FIG. 2 is a flow diagram illustrating the process for fabricating the zone plate according to the present invention;
FIG. 3 illustrates the fabrication process for a precision substrate hole;
FIG. 4 illustrates the inventive deposition process; and
FIG. 5 illustrates the extraction of a small slice containing the desired zone plate pattern according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The two most important parameters for a home-lab based protein crystallography system are the throughput and the quality of diffraction spots. Because a zone plate lens has the best focusing property among x-ray focusing elements as demonstrated by its achievement of sub-100 nm resolution and a large field of view, it provides high quality diffraction data sets with clean diffraction spots. The figure of merit of a zone plate lens in terms of throughput for a zone plate based home-lab protein crystallography system is discussed below.
In general, the flux F (in photons per second) incident on a protein crystal in a home-lab protein crystallography system using a focusing optic such as a zone plate or a reflection based focusing mirror is given by
F=ηB c L 2 Δθ 2 , (1)
where B c , L, and Δθ is the beam brightness, the linear dimension, and the divergence of the illumination beam at the position of the protein crystal, respectively; and η the focusing efficiency of the focusing optic. The beam size L is typically selected either to match the size of the protein crystal or to somewhere in the range of a fraction of a millimeter. The divergence of the beam Δθ is typically in the range of 1-3 mrad (0.06-0.2 degrees).
Expression (1) shows that for a given illumination beam size L and divergence Δθ, F is proportional to the beam brightness B c . It is important to point out that the beam brightness B c at the crystal position is typically smaller than the original source brightness B because the inherent aberration of the focusing optic leads to an increase in the effective source size, i.e., the image of the source is blurred. This effect is similar to the blurring of the image of the sun when looking at the reflection off a surface which is not perfectly flat (e.g. a lake with surface ripples). B c and B are approximately related by
B
c
=
S
2
S
2
+
δ
2
B
,
(
2
)
where S is the diameter of the x-ray source (assuming circular shape) and δ the diameter of the focus spot size of the focusing optic for a point source (point spread function). Expression (2) illustrates that there can be significant degradation of the source brightness B, i.e., B c is smaller than B, if δ is comparable to or larger than S. It is therefore important to have δ much smaller than S to avoid the reduction of the source brightness B by imperfections of the focusing optic. We expect no degradation of the source brightness when a zone plate lens is used as the focusing optic, since they can be fabricated with outstanding precision. On other hand, we expect that there may be substantial degradation with reflection based mirrors that use two successive surface reflections.
Because expressions (1) and (2) show that F is proportional to B, it is important to make the x-ray source as bright as possible. The brightness of an electron bombardment source is proportional to the flux density of energetic electrons impinging on the x-ray target anode. The brightness is limited by the maximum electron density that can be used before melting the target. Two methods have been used to increase the electron density: using a rotating anode to spread the heat over a large area, and using a micro-sized electron spot (microfocus source) to reduce the thermal path to produce a large thermal gradient for better thermal dissipation. The maximum thermal loading of a widely deployed rotating anode (Rigaku UltraX 18) is quoted as 1.2 kilowatt (kW) over an electron spot size of 100 micrometers (www.globalspec.com) and that of a microfocus x-ray source from Hamamatsu is quoted 5W and 10W over an electron spot size of 4 and 7 micrometers, respectively (www.hamamatsu.com). Based on these specifications, one sees that the microfocus x-ray source is about 2.6 and 1.7 times brighter than the rotating anode for the 4 and 7 micrometers x-ray spot sizes, respectively.
An erroneous misconception on the microfocus x-ray source for the protein crystallography application is that it does not have enough x-ray power, i.e., small F. This misconception may originate from the fact that the focusing optic in most of the current home-lab protein crystallography systems is setup to image the source at a magnification close to 1:1 and thus a small source spot would indeed mean a small beam on the protein crystal and thus F would be small according to Expression (1). However, an illumination beam at the crystal with a sufficiently large size and a suitable beam divergence can be produced from a microfocus x-ray source if the focusing optic is configured to magnify the source image on the crystal without blurring it. To utilize the available x-ray flux (brightness) of the microfocus source, the focusing optic has to have a sufficiently large numerical aperture (NA) so that a desired value of Δθ is maintained even in the magnifying geometry. The numerical aperture required for a given source magnification M to keep a desired Δθ is given by
NA=0.5MΔθ. (3)
For example, for M=25 and Δθ=1 mrad (0.057 degree), a focusing optic with a NA of 12.5 mrad is required. For 8 keV x-rays, the corresponding zone plate would have an outermost zone width of about 6 nm. Such a zone plate can not be fabricated using the currently available fabrication technology. It is the goal of the proposed project to overcome the fabrication challenges of zone plates with high NA and utilize them for high throughput home-lab based crystallography systems.
Spatial resolution, modulation transfer function, and throughput are among the most important parameters characterizing the performance of any microscope. The numerical apertures (NAs) of the condenser and objective optics in a microscope are critical in determining these parameters. For x-rays, the NA is given by the half-angle subtended by a lens in respect to the sample.
The magnitude of the NA of an objective directly determines the spatial resolution δ, which is given by
δ
=
0.61
λ
NA
,
(
4
)
where λ is the wavelength of the x-rays. For a zone plate lens, the NA is directly connected to the outermost zone width ΔR:
NA
=
λ
2
Δ
R
(
5
)
The resolution δ therefore is approximately equal to its outermost zone width ΔR, which is determined solely by the smallest zone width that can be fabricated by available technology.
The modulation transfer function (MTF), another very important characteristic of any imaging system, quantitatively describes the degradation of fine feature visibility (attenuation of high spatial frequencies) in the image compared to the features present in the object. Generally the MTF decays in an approximately linear fashion from a value of 1 at zero spatial frequency (full visibility of coarse features) to zero (no visibility) at the frequency cutoff of the imaging system. This cutoff is proportional to the NA, and therefore one needs to maximize the NA for best imaging quality and spatial resolution.
The throughput of a microscope, which corresponds to the time it takes to acquire an image with adequate statistics, depends on the light collection capability of the imaging system and on the focusing efficiency η of the lens. To collect more x-rays and shorten the exposure time, the NA of the condenser and objective lens of a microscope needs to be as large as possible, since the throughput is directly proportional to the accepted solid angle, which is given by approximately π(NA) 2 . For this reason it is desirable to use a NA as large as possible, even if the desired spatial resolution would require only a smaller NA. The most important parameter governing the efficiency η of a zone plate lens is the zone height (or thickness). For optimum efficiency at multi-keV x-ray energies, the desired zone height becomes quite large. In the case of 8 keV x-rays and gold as a zone construction material, a gold thickness of about 1.5 μm would be required to achieve the optimum efficiency.
Specialized imaging modes such as phase contrast and dark field imaging are very important for x-ray microscopy. These imaging modes require high NA optics, for which a closer match between the wavelength of the light and the resolution can be achieved.
In conclusion, the spatial resolution, MTF and throughput critically depend on the availability of high NA lenses, which require zone plates with very fine zones. At the same time the zone thickness has to be kept high to achieve a large focusing efficiency.
The present fabrication method uses thin-film deposition technology which has been used for “sputtered-sliced zone plates” in the past. The thin film technology is a very well established technique to make multilayer mirrors for extreme ultra-violet radiation (EUV). It has been used to produce highly reflective multilayers by alternating deposition of a high-Z and low-Z material in a controlled manner. Layer stacks with many hundreds of periods and period dimensions as small as 6 nm can be produced without significant layer interdiffusion, layer misregistration and residual stress.
FIGS. 1A and 1B are schematic representations of a zone plate lens. Its key parameters are:
the outermost zone width ΔR n which determines the numerical aperture (NA=λ/(2ΔR)) and also the maximum achievable resolution δ(δ=1.22ΔR);
the material and the height (thickness) t of the zones, which determine the achievable focusing efficiency η, and
the diameter OD which determines the maximum usable field of view (field of view ≅⅓ OD).
For x-ray imaging and home-lab based crystallography zone plates are desired with very high resolution and NA and hence very small outermost zone width. The present system can fabricate zone plates with outermost zone width ΔR as small as 5 nm while keeping the zone thickness large (many micrometers) to achieve very good efficiency for hard x-rays.
High-NA zone plates require concentric shells of alternating high- and low-Z materials with very small periods with similar material and layer requirements. In contrast to EUV multilayer optics, which have a large area, small curvature (e.g. a spherical mirror) and constant layer period, for zone plates the multilayers need to be formed as cylindrical shells with a relatively small radius of curvature and layer periods increasing towards the center according to Fresnel's rule.
FIG. 2 illustrates the process for manufacturing the inventive zone plates.
For both extended ultra violet (EUV) multilayer mirrors and x-ray zone plates, it is important to start depositing the layers on a very well defined substrate (i.e. polished for smoothness and right curvature). For EUV mirrors this is achieved by polishing a block of silicon to the desired shape. To avoid the problems that arise from depositing on a wire (“sputtered-sliced” zone plates), we propose to use a substrate that takes the form of a hole such as a blind hole or a through-hole. Since the quality of a zone plate depends most on the outermost zones with the smallest spacing, it is preferred to start depositing the fine zones first. By doing so, the outermost rings will be very well defined and any deposition errors or contamination effects will only affect zones closer to the center, which are much wider and for which the placement accuracy requirement is much more relaxed.
The first and crucial step in the production process of the disclosed x-ray lens is the fabrication of precision holes into a substrate for subsequent thin-film deposition, step 110 . For optimum performance of a zone plate, the RMS error of the diameter has to be smaller than the design resolution and the local roughness of the side wall has to be less than one deposition layer (≈3 nm) to achieve high focusing efficiency.
As illustrated in FIG. 3 , for this purpose, high resolution electron beam lithography is used, in one embodiment, to precisely define the diameter of the photoresist hole 214 into photoresist 210 , that has been deposited on a polished silicon substrate 212 .
After liquid development of the photoresist, an anisotropic etch such as a reactive ion etch or deep reactive ion etch is used to transfer the pattern into the silicon leaving a precisely defined substrate blind hole 216 . The deep reactive ion etch into silicon, called Bosch process, is well understood and widely used in MEMS fabrication. In other embodiments, a through-hole is made completely through the substrate. A tube could even be used.
This process also has the advantage that the resulting sidewall slope can be altered from strictly vertical to under- or overcut leaving a slightly conical shape, i.e., a frustoconical hole. This is achieved by the precise control of the fluorine gas chemistry of the process. One possible application of this control would be to make the sidewall angle such that the outermost zones of the zone plate satisfy the Bragg-condition (giving rise to constructive interference as known from crystal diffraction). This could increase the focusing efficiency of the fabricated zone plate significantly.
Thus, generally, the side wall slope θ is between 0 and 10 degrees, from vertical. The slope is between 0.5 and 10 degrees, for some embodiments, to satisfy the Bragg condition.
In practice, arrays of precision holes comprising a number of hundreds up to tens of thousands will be fabricated in parallel on a single silicon substrate for parallel processing and statistical control.
Another critical step in the proposed fabrication technology is to know precisely the deposition rate and thickness distribution of the layer(s) on the inside wall of the hole.
Returning to FIG. 2 , in the next step after the photoresist layer 210 is stripped or removed, the substrate 212 and the substrate hole 216 are coated with the alternating high- and low-Z material layers according to Fresnel's rule, step 112 . Material combinations include for high Z material: gold, tungsten, copper, silver, and platinum; and for low Z: molybdenum, nickel, silicon, e.g., silicon dioxide, titanium e.g., titanium dioxide, and tantalum e.g., tantalum pentoxide. A initial smoothing layer is first deposited or grown to ensure a smooth sidewall of the hole 216 , in some embodiments. In one example, the smoothing layer is a grown layer of silicon oxide.
Usually a vacuum deposition technique is used such as electron beam evaporation, with or without ion assist. Alternatives are chemical vapor deposition and atomic layer deposition.
As illustrated in FIG. 4 , to get an even coating inside of a precision hole, a planetary motion of the substrate 212 in respect to the source 220 is required (see step 114 of FIG. 2 ). Ideally each precision hole 216 would rotate around its own center axis during deposition. The substrate is moved in the planetary motion with the successive material layers, high-Z and low-Z, are deposited.
Modeling and study of the effects of shadowing and the dependence of the sticking coefficient on deposition angle is required and dependent on the particular deposition system used. These factors need to be carefully taken into account to yield a uniformly thick region inside of the hole that contains the desired zone plate pattern.
After deposition of the thin layer stack, only a small region or cross-section 230 inside the hole 216 contains the desired zone plate pattern as illustrated in FIG. 5 .
To extract the desired slice 230 , the layers in the holes are sectioned. One approach to accomplish this is to adapt a plating and planarization procedure used in semiconductor processing, called damascene process. First, a thin electroplating seed layer is deposited uniformly across the substrate and the inner surface of the hole. In an electroplating process, copper or another suitable material is deposited until the hole is filled completely (see step 116 , FIG. 2 ). Subsequently a chemical mechanical polishing process is used to planarize the substrate surface until the top of the desired slice is exposed in the sectioning process. Ion milling is another alternative.
After bonding the now planar top surface to another flat silicon substrate, step 120 , a similar back thinning and planarization process can be employed until the bottom of the desired slice is exposed (see step 122 , FIG. 2 ). The result is a zone plate on a silicon substrate, which can be used directly for x-ray focusing applications. Alternatively micromachining techniques such as focused ion beam milling can be used to relieve the slice of the zone plate.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A fabrication process for zone plate lenses is based on controlled thin layer deposition for fabricating structures as small as 2 nanometers (nm) in width, and potentially smaller. The substrate for deposition will take the form of a precision hole, fabricated in a substrate, such as silicon by electron beam lithography and subsequent reactive ion etching. A controlled layer deposition is then used to form the required zone plate structure. A subsequent thinning process is used to section the hole and produce a zone plate with the required layer thicknesses. | 6 |
FIELD OF APPLICATION
The present invention relates to novel compounds, viz. sydnonimine derivatives and a method for preparing same. These compounds possess pronounced psychostimulant activity when administered to mammals.
BRIEF SUMMARY OF THE INVENTION
The sydnonimine N-acyl derivatives according to the present invention are novel compounds hitherto unknown in the literature.
In accordance with the present invention, novel sydnonimine N-acyl derivatives have the formula: ##STR4## wherein R is phenyl, β-phenylethyl, dl-α-methyl-β-phenylethyl or l-α-methyl-β-phenylethyl; R' is hydrogen, phenyl; X is a lower alkyl, phenyl, ##STR5## wherein R" is hydrogen, a halogen, a lower fluorinated alkyl; R"' is hydrogen, a halogen, a lower alkyl; when R is dl-α-methyl-β-phenylethyl, R' is H, R" is Cl, R'" is only Cl; when R' is H,X=NHC 6 H 5 , R is only 1-α-methyl-β-phenylethyl; when X is phenyl, R and R' are each only phenyl.
These compounds are white or white with a yellowish tint crystalline substances stable in the air, sparingly soluble in water, soluble in chloroform and less soluble in alcohol.
DETAILED DESCRIPTION OF THE INVENTION
Psychostimulating activity of the compounds according to the present invention has been tested in experiments with mice and rats.
The experiments are performed with white male mice with a weight of 18-20 g and with white rat males with a weight of 120 to 140 g with the account of parameters characterising the influence of the compounds according to the present invention on the central nervous system as well as toxicity. Following this objective, there have been studied:
(1) effect of the compounds on the locomotory activity of the animals (locomotory activity is registered using the instrument "Animex");
(2) capability of the compounds of inducing sterotypic behavior reactions;
(3) capability of enhancing a reflex excitability of the animals with respect to the use of tactile stimuli (air jet pointed from a syringe to an animal);
(4) acute (24-hours) toxicity of the compounds in individually kept mice and mice placed into standard cages with 10 animals in each cage, i.e. so-called "group toxicity".
To quantitatively evaluate the central stimulant activity of the compounds in the tests on mice the values of ED 200 (locomotion) are determined, i.e. doses in which the compounds cause a two-fold potentiation of locomotory activity of the animals; in the tests performed with rats there are determined values of ED 50 (stereotypy), i.e. doses in which the compounds, one hour after their administration, cause, in 50% of the test rats, stereotypic behavior reactions (ED 50 doses are calculated by the Litchfield and Wilkoxsons method).
The compounds according to the present invention are sparingly soluble in water. They were administered to the animals in the form of a suspension prepared with the use of a 1% solution of carboxymethylcellulose with the addition of Tween-80® as an emulsifying agent. Since molecular weights of the test compounds differ from each other, their doses are calculated in mcM/kg.
The compounds according to the present invention provide an exciting effect in the central nervous system which is demonstrated in mice and rats by an enhanced locomotory activity. Thus, minimal doses, which permanently cause a pronounced locomotory hyperactivity in the animals, of the above-mentioned compounds of the formula (1), wherein R is PhCH 2 CH 2 or R is dl-PhCH 2 (CH 3 )CH; with R'=H and X=NHC 6 H 4 Cl-para, or X=NHC 6 H 3 Cl 2 -meta, para-are 7 to 10 mcM/kg, while for the compounds of the formula (1) with R=dl-PhCH 2 (CH 3 )CH, R'=H, at X=NH-C 6 H 4 CH 3 -meta or X=NH-C 6 H 4 CH 3 -para and for the compounds of the formula (1) with R=C 6 H 5 CH 2 CH 2 , R'=H, X=NH-C 6 H 4 CF 3 -meta, minimal active doses are 15 to 20 mcM/kg. The stimulant effect of these doses is observed after 10-15 minutes after administration reaching its maximum after 30-35 minutes at a total duration of the effect of 1.5-2 hours. When these doses are increased by 3-4 times (with mice) and 1.5-2 times (with rats), the intensity and duration of the locomotory hyperactivity is also increased. Further increase in doses results in the origination of stereotypic behavior reactions with the animals which is manifested by swing motions of the head and fore limbs, smelling and licking the cage floor. The stereotypy duration at high doses is 6 to 8 hours.
In a special series of experiments there has been made a quantitative comparison of the central stimulant effect of the compounds according to the present invention as determined by tests of locomotory activity with mice and stereotypy with rats. Certain results of these experiments are presented in the following Table.
TABLE
Activity of the compounds of the formula (1): R=dl-C 6 H 5 CH 2 (CH 3 )CH, R'=H, as by tests for locomotory excitation with mice (ED 200 ) and and stereotypic behavior with rats (ED 50 ).
______________________________________ ED.sub.200 ED.sub.50 (locomotion) (stereotypy),Compounds of the for mice, for rats,present invention mcM/kg mcM/kg______________________________________of the formula (1)wherein:X = NH--C.sub.6 H.sub.4 Cl--para 18.2 20.0X is NH--C.sub.6 H.sub.4 --CH.sub.3 --meta 32.3 39.9______________________________________
The compound of the formula (1) according to the present invention, wherein R is l-PhCH 2 (CH 3 )CH, R'=H, X=NHC 6 H 5 in doses of from 3 to 5 mcM/kg causes a moderate tactile hyperreflexia and in doses of from 6 to 8 mcM/kg, an acute tactile hyperreflexia. The latter is clearly pronounced with mice by a series of strong sudden jumps occurring right at the moment of contact with the air jet. Within the doses range of from 9 to 80 mcM/kg this compound increases the locomotory activity of mice in the direct relationship between this effect value and dose logarithm. The locomotory activity value is doubled upon administration of the dose of ED 200 within the range of from 30 to 35 mcM/kg. With the dose of 40 mcM/kg, the increase in the locomotory activity reaches its maximum within 20 to 30 minutes after the compound administration and is maintained at this level during the next 1-1.5 hour.
In tests on mice, minimal lethal doses (i.e. doses killing 10 to 20% of the test animals) of the compounds according to the present invention are within the range of from 200 to 2,000 mcM/kg which is by 25-100 times higher than the dosage causing a clearly pronounced pharmacological activity-locomotory hyper-activity of mice. It should be noted that toxicity of the compounds is not increased upon administration of the test compounds to the group-housing animals, i.e. there is no phenomenon of "group toxicity" which is characteristic for a series of known psychostimulant compounds such as amphetamine or dextramphetamine.
Therefore, the compounds according to the present invention are low in toxicity and in small doses cause an intensive excitation of animals which is characteristic of psychostimulant preparations.
Known in the art is a derivative of sydnonimine, i.e. dl-N-phenylcarbamoyl-3-(α-methyl-β-phenylethyl) sydnonimine which also possesses a psychostimulant activity. Comparison of this prior art compound with those of the present invention shows however, that the novel compounds according to the present inventions are 2-4 times as active as those of the prior art in experiments with animals. Thus, the known compound, i.e. dl-N-phenylcarbamoyl-3-(α-methyl-β-phenylethyl) sydnonimine is characterized by values of ED 200 of 72.6 mcM/kg (for locomotion) and ED 50 of 107.1 mcM/kg (for stereotype); this means that to achieve the same pharmacological effect, it is necessary to administer doses 2-4 times as high as those of the compounds according to the present invention.
Most active among the compounds according to the present invention include, for example:
l-3-(α-methyl-β-phenylethyl)-N-phenylcarbamoylsydnonimine of the formula: ##STR6## l-N-para-chloro-phenylcarbamoyl-3-(α-methyl-β-phenylethyl) sydnonimine of the formula: ##STR7## N-para-chlorophenylcarbamoyl-3-(β-phenylethyl) sydnonimine of the formula: ##STR8## dl-N-para-chlorophenylcarbamoyl-3-(α-methyl-β-phenylethyl)sydnonimine of the formula: ##STR9##
The novel N-acyl derivatives of sydnonimine according to the present invention are prepared by reacting N-nitro derivatives of N-substituted nitriles of α-aminoacids of the formula: ##STR10## wherein R is phenyl, β-phenylethyl, dl-α-methyl-β-phenylethyl, l-α-methyl-β-phenylethyl; R' is H, phenyl; when R' is phenyl, R is phenyl only;
with an acylation agent in a solvent medium in the presence of a basic-character catalyst, followed by isolation of the desired product. As the acylation agent it is advisable to use haloanhydrides, anhydrides of carboxylic acids or arylisocyanates. It is preferable to use, as the solvent, benzene, toluene, dichloroethane. As the catalyst use can be made of various bases; however, it is better to use, as the catalyst, triethylamine, dimethylbenzylamine, N-methylmorpholine. The reaction is conducted both at room temperature and upon heating, depending on the acylation agent activity. It is preferable to conduct the reaction at a temperature within the range of about 40° to 60° C.
The method according to the present invention is performed in the following manner:
To a solution of N-nitrosoderivatives of N-substituted nitriles of α-aminoacids of the formula (II) there are added a basic-character catalyst and an acylation agent. The reaction mixture is preferably heated to a temperature within the range of from 40° to 60° C. to accelerate the process.
On completion of the reaction the desired product is recovered from the reaction mass by conventional methods.
As the acylation agents in the reaction according to the present invention various electrophilic reagents can be used such as anhydrides and chloroanhydrides of carboxylic acids, arylisocyanates. As the catalyst use can be made of various bases; it has been found that most suitable for the acceleration of the reaction is triethylamine. The reduction proceeds slightly slower in the presence of dimethylbenzylamine, N-methylmorpholine. Other bases can also be used, such as imidazole, pyridine, quinoxaline and the like. The reaction speed substantially depends on the solvent employed while being increased (in the case of triethylamine as the catalyst) in the series: chloroform>hexane>toluene>benzene>chlorobenzene>0-dichlorobenzene>1,2-dichloroethane>nitrobenzene. It is preferred to use toluene or benzene, since the starting compounds are very soluble in these solvents, whereas the reaction products, i.e. corresponding N-acyl derivatives of sydnonimine, are not soluble, as a rule, in these particular solvents, wherefore they are precipitated in their pure form. The reaction can occur in water, but in this case the acylation agent vigorously reacts with water; for this reason, it is more suitable to conduct the reaction in organic hydroxyl-free solvents.
The reaction can be performed at room temperature, especially in the case of active acylation agents; however, the process rate is rapidly increased with increasing temperature. At high temperatures there may occur a thermal decomposition of the starting nitroso derivative, therefore it is preferable to carry out the process at a temperature within an optimal range of about 40° to 60° C. The desired product yield ranges from 80 to 90% of the theoretical.
For a better understanding of the present invention, some specific Examples illustrating the method for preparing the novel N-acyl derivatives of sydnonimine are given hereinbelow.
EXAMPLE 1
To a solution of 5 g of dl-N-nitroso-N-(α-methyl-β-phenylethyl)-aminoacetonitrile in 70 ml of dry benzene there are added 6.7 ml of triethylamine and 5.95 ml of acetic anhydride. After heating for 3 hours at a temperature of 50° C. the reaction mass is evaporated to dryness; the residue is ground with ether; the precipitate is filtered-off, washed with water to give 5.3 g (83.5%) of dl-N-acetyl-3-(α-methyl-β-phenylethyl) sydnonimine melting at 98°-99° C. Found, %: C 63.46; H 6.18; N 17.04. C 13 H 15 N 3 O 2 . Calculated, %: C 63.60; H 6.16; N 17.12.
EXAMPLE 2
To a solution of 1 g of dl-N-nitroso-N-phenyl-α-aminophenylacetonitrile in 10 ml of dry benzene there are added 1.15 ml of triethylamine and 0.49 ml of benzoyl chloride. The reaction mass is evaporated to dryness and the mixture is stirred for 3 hours at a temperature of 50° C.; the residue is treated with dry ether; the precipitate is filtered off and washed with water. The yield of N-benzoyl-3, 4-diphenylsydnonimine is 0.87 g; melting point is 185°-187° C. (with decomposition). Found, %: C 73.75 H 4.46 N 11.73. C 21 H 15 N 3 O 2 . Calculated, %: C 73.90; H 4.44; N 12.31.
EXAMPLE 3
To a solution of 0.70 g of l-N-nitroso-N-(α-methyl-β-phenylethyl) aminoacetonitrile in 7 ml of dry benzene there are added 0.65 ml of triethylamine and 0.42 ml of phenylisocyanate; the mixture is heated for 3 hours at a temperature of 50° C.; then it is cooled. The precipitate is filtered off, washed with benzene, dried and recrystallized from isopropanol to give 0.96 g (86.5%) of the desired product i.e. l-3-(α-methyl-β-phenylethyl)-N-phenylcarbamoylsydnonimine comprising a white powder with a yellowish tint substantially insoluble in water but soluble in fats, acetone, chloroform; its melting point is 150°-152° C. (with decomposition); specific rotation [α] D 20 =-254.5° (acetone, c=1); it has three maximum points in UV-spectrum: λ max =204 nm, 259 nm, 341 nm (ethanol). Found, %: C, 67.41; H 5.74; N 17.23. C 18 H 18 N 4 O 2 . Calculated, %: C 67.06; H 5.63; N 17.38.
EXAMPLE 4
A solution of 2.03 g (0.01 mol) of dl-N-nitroso-N-(α-methyl-β-phenylethy)-aminoacetonitrile, 1.54 g (0.01 mol) of parachlorophenylisocyanate and 1.41 ml (0.01 mol) of triethylamine in 20 ml of dry benzene is heated for 4 hours at a temperature of 50° C.; then the solution is cooled. The precipitate is filtered off, washed with benzene to give 3.0 g (85.4%) of dl-N-para-chlorophenyl carbamoyl-3-(α-methyl-β-phenylethyl) sydnonimine, melting at 218°-130° C. (decomposition). Found, %: C 60.60; H 4.92; N 15.47. C 18 H 17 ClN 4 O 2 . Calculated, %: C 60.59; H 4.79: N; 15.70. 1IR-spectrum, cm -1 : 1,645; 1.590; 1,530; 3,140. PMR-spectrum (in CDCl 3 relative to TMS), δ8.10 ppm; 9.30 ppm.
EXAMPLE 5
The process is conducted in a manner similar to that described in the foregoing Example 4, except that as the catalyst use is made of 5 ml of dimethylbenzylamine (instead of triethylamine); the yield of the desired product is 85% by weight of the theoretical value.
EXAMPLE 6
The process is conducted in a manner similar to that described in Example 4 hereinbefore, except that as the catalyst use is made of 6 ml of N-methylmorpholine (instead of triethylamine); the yield of the desired product is 85% of the theoretical value.
EXAMPLE 7
dl-N-nitroso-N-(α-methyl-β-phenylethyl) aminoacetonitrile is reacted with meta-, para-dichlorophenylisocyanate following the procedure described in Example 4 at a temperature of 40° C. There is obtained dl-N-metal, para-dichlorophenylcarbamoyl-3-(α-methyl-β-phenylethyl) sydnonimine; the yield is 88% of the theory; melting point is 128°-129° C. (with decomposition). Found, %: C 54.92; H 3.85; N 13.94. C 18 H 16 Cl 2 N 4 O 2 . Calculated, %: C 55.20; H 4.13; N 14.31. IR-spectrum, cm -1 : 1,645; 1,580; 1,515. PMR-spectrum (in CDCl 3 relative to TMS) δ8.12, 9.52 ppm.
EXAMPLE 8
dl-N-nitroso-N-(α-methyl-β-phenylethyl)aminoacetonitrile is reacted with meta-trifluoromethylphenylisocyanate in a manner similar to that described in Example 4 hereinbefore. There is obtained dl-N-meta-trifluoromethylphenylcarbamoyl-3-(α-methyl-β-phenylethyl)sydnonimine; the yield is 81.5% of the theory; melting point is 150°-152° C. (with decomposition). Found, %: C 58.22; H 5.10; N 14.26. C 19 H 17 F 3 N 4 O 2 . Calculated, %: C 58.50; H 4.10; N, 14.37. IR-spectrum, cm -1 : 1,642; 1,595; 1,540, 3,168. PMR-spectrum (in CDCl 3 , relative to TMS) δ: 8.14; 9.56 ppm.
EXAMPLE 9
N-nitroso-N-(β-phenylethyl aminoacetonitrile is reacted with meta-para-dichlorophenylisocyanate following the procedure described in Example 4 hereinbefore. There is obtained N-meta-, para-dichlorophenylcarbamoyl-3-(β-phenylethyl) sydnonimine; the yield is 85.5% of the theory; melting point is 137°-138° C. (with decomposition). Found, %: C 54.26; H 3.97; N 14.95. C 17 H 14 Cl 2 N 4 O 2 . Calculated, %: C 54.12; H 3.74; N 14.85. IR-spectrum, cm -1 : 1,653; 1,580; 1,510. PMR-spectrum (in CDCl 3 relative to TMS), δ: 8.08; 9.52 ppm.
EXAMPLE 10
N-nitroso-N-(β-phenylethyl)aminoacetonitrile is reacted with meta-trifluoromethylphenylisocyanate following the procedure described in the foregoing Example 4 to give N-meta-trifluorophenyl carbamoyl-3-(β-phenylethyl)-sydnonimine; the yield is 82.2% of the theoretical value; melting point is 143°-145° C. (with decomposition). Found, %: C 57.60; H 4.12; N 14.59. C 18 H 15 F 3 N 4 O 2 . Calculated, %: C 57.30; H 4.02; N 14.89. IR-spectrum, cm -1 : 1,640; 1,595; 1,538; 3,165. PMR-spectrum (in CDCl 3 relative to TMS), δ8.12; 9.52 ppm.
EXAMPLE 11
dl-N-nitroso-N-(α-methyl-β-phenylethyl)aminoacetonitrile is reacted with para-tolylisocyanate following the procedure described in Example 4 at a temperature of 60° C. There is obtained dl-N-para-tolylcarbamoyl-3-(α-methyl-β-phenylethyl)sydnonimine; the yield is 85% of the theoretical value; melting point is 128°-130° C. (with decomposition) Found, %: C 67.62; H 5.91: N 16.62. C 19 H 20 N 4 O 2 . Calculated, %: C 67.91; H 5.93; N 16.63. IR-spectrum, cm -1 : 1,645; 1,595; 1,540. PMR-spectrum (in CDCl 3 relative to TMS) δ8.10; 9.07 ppm.
EXAMPLE 12
The process is conducted in a manner similar to that described in Example 4, except that toluene is used as a solvent. The yield of the desired product is 86% of the theoretical value.
EXAMPLE 13
The process is conducted in a manner similar to that described in the foregoing Example 4, except that dry dichloroethane is used as a solvent. On completion of the reaction, the reaction mass is evaporated to dryness; the residue is ground in ether, filtered-off and recrystallized from isopropanol. The yield of the desired product is 80% of the theoretical value. | N-acyl sydnonimines of the formula: ##STR1## wherein R is phenyl, β-phenylethyl, dl-α-methyl-β-phenylethyl or l-α-methyl-β-phenylethyl; R' is hydrogen, phenyl; X is a lower alkyl, phenyl, ##STR2## wherein R" is hydrogen, a halogen, a lower fluorinated alkyl; R'" is hydrogen, a halogen, a lower alkyl; when R is dl-α-methyl-β-phenylethyl, R' is H, R" is Cl, R'" is only Cl, while when R' is H, X is NHC 6 H 5 R is only l-α-methyl-β-phenylethyl; when X is phenyl, R and R' are each phenyl only.
The method for preparing sydnonimine N-acylderivatives comprises reacting N-nitrosoderivatives of N-substituted nitriles of α-aminoacids of the formula: ##STR3## wherein R is phenyl, β-phenylethyl, di-α-methyl-β-phenylethyl or l-α-methyl-β-phenylethyl; R' is H, phenyl; when R' is phenyl R is phenyl only, with an acylation agent in a solvent medium in the presence of a basic-character catalyst, followed by isolation of the desired product. | 2 |
[0001] The present invention relates to a composition as a preventive temporary fire protection agent, its application onto products, its production and its use for the containment of bush and grass fires.
STATE OF THE ART
[0002] The term fire retardant refers to organic and/or inorganic substances that are intended to render particularly wood and wood materials, plastics and textiles flame-resistant. These substances achieve this in that they prevent the ignition of materials that are to be protected. (Römpp-Lexikon Chemie [Römpp's Encyclopedia of Chemistry], published by Georg Thieme Verlag 1997, 10 th Edition, Stuttgart/New York, page 1352 f).
[0003] According to Wikipedia, fire retardants are broken down into inorganic fire retardants including, among others, ammonium phosphates as well as into halogenated fire retardants, organophosphorous fire retardants and nitrogen-based fire retardants, including, among others, urea.
[0004] A non-toxic fire retardant based on ammonium dihydrogen phosphate (=monoammonium phosphate) is advertised and sold on the Internet under the name Antiflame®.
[0005] Cotton fabrics can be rendered flame-retardant by means of ammonium polyphosphates that are (in)soluble in water (British patents GB-A-1069946, GB-A-1504507).
[0006] East German patent DD 287 550 A5 relates to an aqueous formulation for rendering substances flame-resistant and containing 7% to 24% by weight of a fluoropolymer dispersion in addition to ammonium phosphate, water and urea, and it also relates to a method for rendering a substrate fire-resistant by means of impregnation, drying and curing.
[0007] European patent application EP 449 159 B1 (=Japanese patent application JP-A-4214471) relates to a fire-retardant finish consisting of a water-soluble and a water-insoluble ammonium polyphosphate, a surfactant, a heat-curable synthetic resin, urea and water, and it also relates to a method to create a flame-retardant finish for woven and non-woven materials, especially those made of cellulose, by means of impregnation and heat-curing.
[0008] The above-mentioned publications relate to heat-curing formulations containing binders that provide textiles with a permanent flame-retardant finish, but they do not relate to is preventive temporary fire protection agents.
DESCRIPTION OF THE INVENTION
[0009] The present invention is based on the objective of providing a special composition which consists of only two active ingredients as a preventive temporary fire protection agent and which, unlike the halogenated fire retardants and the organophosphorous fire retardants, is safe to use and is applied onto the product to be protected against fire very rapidly and easily.
[0010] This objective is achieved by a preventive temporary fire protection agent.
[0011] Therefore, the invention relates to the use of a composition as a temporary fire protection agent, containing
2.0% to 23% by weight, preferably 2.0% to 15% by weight, especially 3.0% to 14.5% by weight, of diammonium hydrogen phosphate (=diammonium phosphate); 1.0% to 17% by weight, preferably 1.0% to 10% by weight, especially 1.0% to 2.5% by weight, of urea; 60% to 97% by weight, preferably 75% to 97% by weight, especially 83% to 96% by weight, of water.
[0015] The term preventive “temporary fire protection agent” relates to the readily water-soluble composition defined in the claims, which is applied prior to a fire onto the surface of the products to be protected against fire. If the substrate is absorbent, the active components diffuse into the objects to be protected, whereas if the material is not absorbent, they remain on the surface and form a colorless protective film.
[0016] Therefore, the subject matter of the present invention is not a fire extinguishing agent that is only applied to the source of the fire after the onset of the fire.
[0017] The subject matter likewise does not comprise impregnations, in other words, the impregnation of porous flammable materials in order to render them permanently fire resistant.
[0018] According to a preferred embodiment, the composition employed as a preventive temporary fire protection agent contains, relative to 100 parts by weight of the composition, 0% to 1% by weight of at least one chelating agent, whereby the chelating agent is selected from among polyoxycarboxylic acids, polyamines, EDTA and/or NTA.
[0019] According to another preferred embodiment, the composition contains, relative to 100 parts by weight of the composition, 0% to 7% by weight of familiar auxiliaries and additives, which are selected from among cross-linking agents, binders and thickeners as well as dyes.
[0020] According to another preferred embodiment, the composition contains, relative to 100 parts by weight of the composition, 0% to 1% by weight of a water softener, especially an alkali phosphate, and/or 0% to 3% by weight of surfactants, particularly anionic, non-ionogenic or amphoteric surfactants or mixtures thereof, and/or 0% to 3% by weight of binders or thickeners, especially water-soluble cellulose derivatives or other water-dilutable film-forming agents, depending on the substrate to be protected or on the application, and/or 0% to 0.2% by weight of water-soluble dyes.
[0021] According to a preferred embodiment, the products treated is with the composition are paper, pasteboard, cardboard, decorations, deciduous trees, coniferous trees, bushes, shrubs, grasses, parts thereof, arrangements thereof or products thereof.
[0022] Examples of such products are decoration materials (garlands, paper lanterns, paper flowers), wood derivatives, brush wood in forests, bushes, hay, straw, dried flowers.
[0023] According to another preferred embodiment, the flammable product is a deciduous tree or a coniferous tree, parts thereof or arrangements thereof, a Christmas tree, a holiday wreath or an evergreen arrangement.
[0024] Production:
[0025] Another subject matter of the present invention is the provision of a production method for the above-mentioned composition.
[0026] This is achieved by means of the features of the production claim.
[0027] Therefore, the invention relates to methods for the production of the composition of the type described above, whereby first of all 2.0 to 23 parts by weight of diammonium hydrogen phosphate and 1.0 to 17 parts by weight of urea and, if applicable, the above-mentioned auxiliaries and additives, are brought into contact with each other, especially mixed together, optionally ground up and then dissolved in 60 to 97 parts by weight of water.
[0028] Application of the composition:
[0029] Moreover, the present invention relates to a method for applying the composition onto a specific flammable product.
[0030] This objective is achieved by means of the features of the other method claims.
[0031] Thus, the invention relates to a method for applying the composition of the type described above, whereby an aqueous solution consisting of 2.0% to 23% by weight, preferably 2.0% to 15% by weight, especially 3.0% to 14.5% by weight, of diammonium hydrogen phosphate, 1.0% to 17% by weight, preferably 1.0% to 10% by weight, especially 1.0% to 2.5% by weight, of urea, 60% to 97% by weight, preferably 75% to 97% by weight, especially 83% to 96% by weight, of water is applied continuously or discontinuously onto the surface of the flammable product.
[0032] In the method according to the invention, preference is given to carrying out the application by means of injecting, spraying, rolling, dipping, impregnating or brushing, followed by drying at ambient temperature.
[0033] Concentrate:
[0034] Another subject matter of the present invention is the provision of a concentrate for preventive temporary fire protection that can be converted on site into the appropriate aqueous composition.
[0035] This objective is achieved by means of the features of the concentrate claim.
[0036] Thus, the invention relates to a concentrate for preventive temporary fire protection consisting of
[0037] 60% to 95% by weight of diammonium hydrogen phosphate,
[0038] 5% to 39% by weight of urea, and
[0039] 0% to 1% by weight of alkali phosphate.
[0040] Uses:
[0041] The subject matter of the present invention is likewise the use of two active ingredients in combination with a solvent as a flame-retardant agent for the containment of bush and grass fires.
[0042] This objective is achieved by means of the features of claim 11 .
[0043] Thus, the invention relates to the use of a composition consisting of 2.0% to 23% by weight, preferably 2.0% to 15% by weight, especially 3.0% to 14.5% by weight, of diammonium hydrogen phosphate, 1.0% to 17% by weight, preferably 1.0% to 10% by weight, especially 1.0% to 2.5% by weight, of urea, 60% to 97% by weight, preferably 75% to 97% by weight, especially 83% to 96% by weight, of water, as a preventive temporary fire protection agent.
[0044] According to a preferred embodiment, the above-mentioned composition is employed to create a flame-retardant finish for flammable materials such as deciduous trees or coniferous trees or products thereof, especially parts of these trees or arrangements thereof, a holiday wreath or an evergreen arrangement as well as other products of plant origin.
[0045] Another subject matter of the present invention is the use of the finish as a preventive protection agent against fire, especially for the containment of bush and grass fires.
[0046] Thus, the invention relates to the use of a composition consisting of 2.0% to 23% by weight, preferably 2.0% to 15% by weight, especially 3.0% to 14.5% by weight, of diammonium hydrogen phosphate, 1.0% to 17% by weight, preferably 1.0% to 10% by weight, especially 1.0% to 2.5% by weight, of urea, 60% to 97% by weight, preferably 75% to 97% by weight, especially 83% to 96% by weight, of water, as a preventive temporary fire protection agent, is especially for the containment of bush and grass fires.
[0047] Therefore, the invention relates to the use of the flame-retardant finish of the above-mentioned type and/or the application according to the above-mentioned method, as a preventive protection agent against fire, for preventing the propagation of flames in the case of flammable organic materials.
EMBODIMENTS
[0048] The present invention will be elaborated upon in greater detail below by embodiments in the form of production examples and application examples, which demonstrate that the composition according to the invention can be employed as a preventive temporary fire protection agent.
Production Example
[0049] A mixture consisting of 18 kg of diammonium hydrogen phosphate, 11.7 kg of urea and 0.3 kg of sodium polyphosphate is ground up in a ball mill or cone mill until it is homogeneous. The resultant fine-grained pulverulent mixture dissolves quickly and residue-free in 100 liters of water.
Application Example 1
[0050] An amount of 100 liters of the 30%-solution described above were sprayed onto a large open terrain containing dry bushes and grasses over a circular surface area of about 150 square meters using a motor-powered pressurized spraying device, so that the bushes and grasses within the circular area were uniformly wetted. Once the sprayed solution had dried, the area was set on fire in the wind direction towards the circular area under the supervision of the fire department. The result was that the bushes and grasses on the open area were consumed by the fire while the plants treated with the flame retardant inside the circular area were spared. The residues of the composition according to the invention on the plants that had not burned are not harmful to nature since they are washed off by rain and they then act as fertilizer.
Application Example 2
[0051] A solution consisting of 15% by weight of diammonium hydrogen phosphate, 5% by weight of urea, 2% by weight of anionic and non-ionogenic surfactants in 78% by weight of water was sprayed onto pine tree branches by means of a spray bottle. After the branches had dried, an attempt was made to set fire to them using a candle. It was found that it was much more difficult to ignite the pine tree branches treated with the preventive temporary fire-protection agent than the untreated branches in a comparative experiment. Moreover, the afterglow in the treated specimen was markedly reduced.
Application Example 3
[0052] The test below shows the preventive temporary fire-protection effect of the composition according to the invention in 5% to 20%-aqueous solutions at different concentrations of the two active ingredients.
[0000]
Test series A - 20%-solutions
Diammonium
Visual assessment
Water
Urea
phosphate
of flame protection
A1
100 g +
2 g
18 g
1
A2
100 g +
5 g
15 g
1
A3
100 g +
10 g
10 g
2
A4
100 g +
15 g
5 g
3
A5
100 g +
20 g
0 g
5
[0000]
Test series B - 10%-solutions
Diammonium
Visual assessment
Water
Urea
phosphate
of flame protection
B1
100 g +
1.0 g
9.0 g
1-2* )
B2
100 g +
2.5 g
7.5 g
1-2
B3
100 g +
5.0 g
5.0 g
3
B4
100 g +
7.5 g
2.5 g
4
B5
100 g +
10.0 g
0.0 g
5
[0000]
Test series C - 5%-solutions
Diammonium
Visual assessment
Water
Urea
phosphate
of flame protection
C1
100 g +
0.50 g
4.50 g
2-3
C2
100 g +
1.25 g
3.75 g
2-3
C3
100 g +
2.50 g
2.50 g
4
C4
100 g +
3.75 g
1.25 g
5
C5
100 g +
5.00 g
0.00 g
5
Execution of the Experiment
[0053] Strips of absorbent paper were impregnated over half of the surface with the above-mentioned solutions and dried in air. The papers were subsequently hung with the non-impregnated side facing down and then ignited by placing a tea candle underneath them. The unprotected segments burned up completely in all cases. The flame-retardant effect was assessed visually by comparing the unburned residual lengths of the impregnated segments.
Grade 1 excellent flame protection (unburned residual length of 80% to 100%) Grade 2 good flame protection (unburned residual length of 60% to 80%) Grade 3 clearly recognizable flame-retardant effect (unburned residual length of 30% to 60%) Grade 4 weak flame-retardant effect (unburned residual length<30%) Grade 5 no detectable flame-retardant effect (paper burns up)
Conclusion Regarding Application Example 3
[0059] In comparison to diammonium hydrogen phosphate, urea does not exhibit any significant flame-retardant effect of its own. The effect of diammonium hydrogen phosphate is pronounced and increases with the application concentration. Apparently, however, some of the effective diammonium hydrogen phosphate can be replaced by urea without impairing the preventive temporary fire protection.
DECLARATION CITED IN ARTICLE 19(1)
[0060] As is explained on page 3, in the last three paragraphs of the present description as well as in claims 5 , 12 , the subject matter of the present invention is a readily water-soluble composition consisting of two active ingredients, which is applied prior to a fire onto the surface of the products to be protected against fire (in other words, finished products, commercial products). If the substrate is absorbent, the active components diffuse into the objects to be protected whereas, if the material is not absorbent, they remain on the surface and form a colorless protective film. Consequently, the present invention does not relate to a fire extinguishing agent and it likewise does not relate to impregnations that are applied onto a semi-finished product, a preliminary product, during the production process.
[0061] According to page 4 of international patent application WO 90/13699 A2, this publication has the objective of putting forward a ternary flame-retardant composition containing, in addition to urea and monoammonium phosphate or diammonium phosphate, at least one ammonium halide (for instance, ammonium chloride) as the essential component of the composition. This additional component is not needed according to the invention. Perhaps it is precisely the ammonium halides in this mixture that have a synergistic or catalytic effect. According to page 6, the flame protection is achieved by impregnating textiles and wood products. Moreover, claims 15 to 18 claim the preparation as a fire-extinguishing agent (extinguishing water) but not to preventive temporary fire protection to which the present invention is restricted, for example, in case of bush fires.
[0062] According to page 2 of German patent application DE 18 17 535 A1, this publication has the objective of creating a printable paper that does not burn in air or in a pure oxygen atmosphere. This objective is achieved in that during the industrial paper-production process, the raw paper is impregnated with an aqueous solution of flame-retardant substances such as diammonium phosphate and urea, then smoothed and finally compacted, as can be gleaned from Example 2. A preventive temporary treatment of a final product or finished product with the composition according to the invention that can serve to fight fires, especially bush fires, is neither disclosed nor suggested there.
[0063] European EP-A-0 277 932 relates to the thickening of is aqueous flame-protection concentrates. Diammonium phosphate, among others, is mentioned as one of the described flame-retardant constituents, but urea is not mentioned. In contrast to the thickened aqueous concentrates, our preparation is a powder without thickening agents.
[0064] U.S. Pat. No. 4,264,320 relates to the production of black textiles with a flame-resistant finish created by impregnation and subsequent heating to at least 220° C. [428° F.]. Except for the components diammonium phosphate and urea, which were cited among others, this patent does not have anything in common with the invention being claimed, that is to say, preventive temporary firefighting.
[0065] U.S. Pat. No. 2,935,471 relates to flame-retardant preparations using, among other things, diammonium phosphate, but not using urea. Moreover, boron compounds are essential constituents of the composition known from the state of the art. Furthermore, the textiles and paper are impregnated at 135° C. [275° F.].
[0066] British Patent 2,301,122 relates to flame-retardant compositions. However, the preventive temporary fighting of fires, especially bush fires, is neither disclosed nor suggested there. | The invention relates to the use of a composition as a preventive temporary fire protection agent, said composition containing: between 2.0 wt. % and 23 wt. %, preferably between 2.0 wt. % and 15 wt. %, especially between 3.0 wt. % and 14.5 wt. %, of diammonium hydrogen phosphate; between 1.0 wt. % and 17 wt. %, preferably 1.0 wt. % and 10 wt. %, especially between 1.0 wt. % and 2.5 wt. % of urea; and between 60 wt. % and 97 wt. %, preferably between 75 wt. % and 97 wt. %, especially between 83 wt. % and 96 wt. % of water. The invention also relates to the application of said composition and to the production and use thereof as a preventive protection agent for checking forest fires and steppe fires. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Patent Application No. PCT/EP2011/051349, filed on Feb. 1, 2011, and designating the U.S., which has been published in German and claims priority from German Patent Application No. DE 10 2010 007 401.2 filed on Feb. 3, 2010. The entire contents of these prior applications are incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to an apparatus and a method for automatically forming and filling containers, such as water bottles.
[0003] Heretofore, such apparatus are primarily used in industry, in particular in the beverage industry. The apparatus (or plants) are operated stationarily and the workstations and conveyers required are permanently installed in a large production building. Stationary plants are designed for high throughput rates which, for example in the field of the beverage industry, might be of the order of up to 40,000 bottles per hour. In order to achieve this, high-performance workstations and conveyers are employed.
[0004] EP 0 950 606 B1 discloses a stationary machine for automatically forming and filling containers. For this purpose, this machine has a container forming station designed as a blowing station. By means of the blowing station, bottles are formed from bottle preforms, which are composed of a thermoplastic material, under the action of heat and of compressed air. The bottles are filled in a workstation and are subsequently closed in a closing station. Grippers are used as a conveyer, by means of which the bottles are moved between the individual workstations.
[0005] EP 1 606 371 B1 discloses a plant in which a conveyer constructed from clamping jaws is employed. The clamping jaws are arranged on both sides of the bottles, specifically transversely to their transport direction, in each case in the manner of a rake. The bottles are moved forward by the left and right clamping jaws being displaced alternately. Plants are also known, the conveyers of which are constructed from what are known as transport stars, entry stars and exit stars, as is described, for example, in DE 10 2005 015 565 A1 or in DE 199 28 325 A1.
[0006] The stationary plants described above have in common that they all have conveyers where the movement of the bottle preforms and of the bottles between the individual workstations involves hand-over movements or grip-around movements. In a gripper-based conveyer, the movement of the bottles takes place in such a way that the bottles are picked up by various grippers in a sequence defined by the processing flow and are thus moved between the individual workstations. Even in the case of a conveyer constructed from transport stars, entry stars and exit stars, the bottles are moved forward by being handed over again and again. In both types of conveyers, the container preform or the container is grasped at a first location, such as at a first workstation, by a transport element, such as a gripper or a transport star, in order then to be delivered at a second location. In a conveyer of rake-like type, the bottles are moved forward by being again and again gripped around by the left and right clamping jaws.
[0007] The hand-over movements and grip-around movements involve relative movements. On the one hand, they involve relative movements between a transport element of the conveyer and the article to be transported and thus to be grasped, as is the case in a gripper-based conveyer, a conveyer constructed from transport stars, entry stars and exit stars, or a conveyer of rake-like type. These relative movements are therefore relative movements between a transport element and an article spatially separated from the latter. On the other hand, they involve relative movements between individual transport elements of the conveyer itself, as is the case in a conveyer constructed from transport stars, entry stars and exit stars or a conveyer of rake-like type. In order to enable such relative movements, the individual components of the conveyer must be oriented very accurately with one another and with respect to the workstations when a plant is set up. Comprehensive adjustment and leveling work is therefore necessary when a plant is being set up and can usually be carried out only by specially trained personnel.
[0008] The result of the complicated adjustment and leveling work is that the known plants are not suitable for mobile use. A mobile use is desirable, however, when a large number of people are to be catered far away from civilization for a lengthy period of time. Typical applications may include military training exercises or deployments of major military units, but also humanitarian commitments, for example during disaster aid in an earthquake zone. Mobile water treatment devices are already available, inter alia, by the present assignee. By means of mobile water treatment devices, raw water, such as water from a stagnant pool discovered in the region of action can be treated to produce drinking water. However, bottle filling as in the beverage industry has not been possible so far under the rough circumstances of a mobile use.
[0009] An apparatus for automatically forming and filling containers for mobile applications should be of highly robust design. On the one hand, it should withstand transport into the region of action. On the other hand, it should function reliably even under rough operating conditions and after setting up and dismantling. Moreover, it should be capable of being put into operation again after a change of location without complicated setting and adjustment work. It should also be simple to repair. The apparatus known from the prior art do not fulfill these requirements.
SUMMARY
[0010] Against this background, it is an object of the present invention to provide an apparatus and a method that allow to form and fill containers with water or other kinds of fluids under adverse conditions of use, such as exist during mobile use, for example. It is another object to provide an apparatus and a method that are simple to use and can reliably operated to provide water bottles or other kinds of prefilled containers in large quantities. It is yet another object to provide an apparatus for forming and filling containers, such as water bottles, that has a compact construction which allows transport and deployment using conventional military transport equipment.
[0011] In view of the above, there is provided an apparatus for automatically forming and filling containers, comprising a plurality of workstations and a conveyer that comprises a number of container carriers and a number of movement units for moving the container carriers, with the plurality of workstations at least comprising an insertion station, a container forming station, a filling station, a closing station, and an ejection station, with the insertion station being designed for feeding a container preform into one from the number of container carriers, thereby assigning the container preform to said one container carrier, with the container forming station being designed for forming a container from the container preform, with the filling station being designed for filling the container with a fluid, with the closing station being designed for closing the filled container, and with the ejection station being designed for ejecting the filled and closed container out of said one container carrier, wherein the conveyer is designed for moving the container carriers from the insertion station via the container forming station, the filling station and the closing station to the ejection station, and wherein the container preform and the container formed from the prefoun continuously reside in said one container carrier while the conveyor moves said one container carrier from the insertion station via the container forming station, the filling station and the closing station to the ejection station.
[0012] There is also provided a method for automatically forming and filling containers by means of an apparatus which has a conveyer and a plurality of workstations comprising an insertion station, a container forming station, a filling station, a closing station and an ejection station, the method comprising the steps of feeding a container preform into a container carrier by using the insertion station, thereby assigning the container preform to the container carrier; forming a container from the container preform by using the container forming station; filling the formed container with a fluid by using the filling station; closing the filled container by using the closing station; and ejecting the filled and closed container out of the container carrier by using the ejection station; wherein the container carrier is moved from the insertion station via the container forming station, the filling station and the closing station to the ejection station by means of the conveyer; and wherein the container preform and the container formed from the preform continuously reside in the container carrier assigned to the container preform.
[0013] The novel apparatus and method are based on the idea of inserting the container preform into a container carrier and of leaving the container preform and the container formed from the preform in this container carrier during the entire processing flow. The container preform and the container are moved together with the container carrier, into which the container preform is inserted at the beginning of a defined processing flow, between the individual workstations (preferably all the workstations). They also remain in the assigned container carrier at the individual workstations. At the container forming station, the container is formed from the container preform inserted into the container carrier. The container then located in the container carrier is subsequently filled at the filling station and closed at the closing station. The assignment of container and container carrier ends only at the ejection station where the closed container is extracted from the container carrier. The container preform and the container formed from the preform are thus moved between the individual workstations, without any hand-over movements or grip-around movements being necessary for this purpose. In the novel apparatus, none of the above-described relative movements occur between the transport element of the conveyer and the article to be transported. The movement of the container preform and of the container between the individual workstations does not involve any relative movement in the sense of a hand-over movement or grip-around movement of the container preform or of the container with respect to the container carrier into which the container preform is inserted.
[0014] Since the novel apparatus and the novel method manage without relative movements, they can both be put into operation without complicated setting and adjustment work after the apparatus has been set up, for example even on uneven ground. In addition, in comparison with the known apparatus, the novel apparatus manages with a smaller number of movement-inducing components in order to move a container preform and a container between the individual workstations. Furthermore, in the novel apparatus, these components are of less complex construction. Moreover, the movements or movement sequences to be carried out in order to move the container perform and the container are less complex.
[0015] The novel apparatus and the novel method are therefore highly robust and operate reliably even under adverse conditions of use, such as occur, for example, during mobile use. Moreover, the novel apparatus and the novel method can be handled in a simple way and can therefore be put into operation even by persons without much specialized knowledge.
[0016] In a refinement of the invention, the movement units are designed for moving the container carrier on a closed trajectory.
[0017] This refinement enables the apparatus to have a compact construction. Moreover, it has the effect that the apparatus can be operated easily and the production process can easily be monitored, since the individual workstations can be arranged in a small space and therefore the distances between the individual workstations are short.
[0018] In a further refinement, the conveyer has a first and a second movement unit, the first movement unit being designed for moving the container carrier along a first movement direction, the second movement unit being designed for moving the container carrier along a second movement direction, and the second movement direction being oriented essentially orthogonally to the first movement direction.
[0019] This refinement has the advantage of simple movement sequences between the individual workstations. The result of this is that the apparatus can be handled simply and operates reliably. Also, this refinement makes it possible to have a compact construction. Preferably, the container carrier is moved away from the insertion station along the first movement direction and is moved toward a second workstation, specifically the container forming station, along the second movement direction.
[0020] In a further refinement, the conveyer has a third movement unit which is designed for moving the container carrier along a third movement direction, the third movement direction being oriented essentially orthogonally to the second movement direction.
[0021] This refinement, too, makes it possible to implement simple movement sequences and therefore the construction of a compact, simple-to-handle and reliably operating device. Preferably, the container carrier is moved toward a third workstation, specifically the filling station, along the third movement direction.
[0022] The conveyer may, in a further refinement, have a fourth movement unit designed for moving the container carrier along a fourth movement direction, the fourth movement direction being oriented essentially orthogonally to the third movement direction.
[0023] This refinement makes it possible to have a rectilinear closed movement sequence and therefore a highly compact construction of the device. The container carrier moves on a closed path. Preferably, the container carrier is moved along the fourth movement direction via a third workstation, in particular the closing station, and via a fourth workstation, in particular the ejection station, toward the insertion station.
[0024] In a further refinement, the movement units are designed for moving the container carriers in translational motion.
[0025] This refinement has the advantage that the container carriers are moved between the individual workstations by means of uniaxial movements. Consequently, the use of grippers, for example, may be dispensed with. Instead, movement units of simple design may be employed. As a result, the novel apparatus can be constructed in a simple way, can be handled simply and also operates reliably. Advantageously, the movement units may be designed as pneumatic cylinders or as electric drives, in particular as servomotors, with servomotors preferably being employed because they are especially simple to handle.
[0026] In a further refinement, the movement units are designed for moving the container carriers essentially within a predefined movement plane.
[0027] This refinement makes it possible to have a simple movement sequence and therefore a simple-to-handle and reliably operating device. No superposed multiaxial movements are necessary for moving the container carriers between the individual workstations. The apparatus may be designed to be gripper-free. Advantageously, the movement plane lies essentially parallel to a plane which is defined by the ground on which the workstations and the conveyer stand. In other words, in this refinement, the container carriers are moved essentially or even continuously horizontally.
[0028] In a further refinement, the insertion station is designed for inserting the container preform into the container carrier from above as a result of a gravity-induced movement.
[0029] This refinement makes it possible to insert the container preform into the container carrier in an especially simple way. Since insertion takes place by utilizing gravity and therefore passively, the use of a movement unit, for example a gripper, may be dispensed with. Nor is there any need for adjustment and setting work here. Insertion of the container preform into the container carrier from above consequently has advantages in relation to insertion from below. It is thus possible to construct a simple-to-handle and reliably operating device. Moreover, this makes it possible to construct a simple and reliably operating apparatus which can also be handled in a simple way.
[0030] In a further refinement, the container carrier has a spring element which is designed for holding a container prefoiin inserted into the spring element from above and for making it possible to extract a filled container downward.
[0031] This refinement makes it possible to implement a container carrier of simple design. The spring element, on the one hand, ensures that a container preform inserted into the container carrier is held reliably. On the other hand, on account of its elastic properties, it makes it possible to extract a filled container, in particular a filled and closed container, without difficulty. Since the body region of a container has a larger diameter than its neck region, the container cannot simply be extracted upward out of the spring element and therefore out of the container carrier. Downward extraction is advantageous. This is possible on account of the elastic properties of the spring element. Moreover, the spring element, because of its simple construction, is a holding component which is beneficial to produce. The spring element performs the actual function of holding the container carrier vertically.
[0032] In a further refinement, the spring element is dimensioned such that the filled container falls out downward by itself due to gravity.
[0033] This refinement contributes to a simple construction and therefore to simple handling and reliable operation of the apparatus. There is no need for any movement components by means of which the filled container is “actively” extracted out of the container carrier. Instead, extraction takes place passively on account of the intrinsic movement of the filled container. With this dimensioning of the spring element, guidance in the region below the containers is advantageous, commencing with the filling station and as far as the ejection station, so that the filled containers are prevented from falling out of the spring element and therefore out of the container carrier prior to the desired ejection.
[0034] In a further refinement, the container preform has a neck region with a collar, the spring element being designed as a thin annular disk with an inner edge and with an outer edge.
[0035] In this case, a container preform inserted from above is held by being gripped under its collar, a filled container being extractable downward, as before. This refinement has a number of advantages. The collar in the neck region of the container preform constitutes a defined point on the latter which is preserved even when the forming of the container is taking place in the container forming station. Thus, the container preform and the container formed from the preform can be moved in an unchanged position and attitude through the complete device, i.e., between the individual workstations. Both the container preform and the container are supplied to the individual workstations in a defined position and attitude, and therefore work at the individual workstations, in particular the production and filling of the container, can be carried out reliably. The holding position defined by the collar is a uniform holding position regardless of type and quality of differently designed containers. The novel apparatus can therefore be used for different container forms. Since the container is held in the container carrier by being gripped under the collar, the container can be closed in the closing station, without having to be extracted from the container carrier for this purpose. There is therefore no need for any transfer. Since the spring element is designed as a thin disk, in spite of being positioned below the collar of the container preform it has no influence upon the container blowing operation taking place inside the container forming station. By the container preform and the containers being picked up at their collar, the size and form of the container body has virtually no influence upon the configuration of the conveyer. The conveyer and therefore the apparatus can consequently be converted in a simple way with regard to containers of different volumes and foiins.
[0036] In a further refinement, the disk has a plurality of slots.
[0037] Advantageously, the slots run, commencing at the inner edge of the disk, over part of the ring width into the direction of the outer edge of the disk. This refinement gives the disk a high elasticity. Overall, simple and reliable ejection of the closed container in the ejection station becomes possible, thus contributing to simple handling and reliable operation of the device.
[0038] In a further refinement, the workstations and the conveyer are arranged in a transportable enclosure for mobile use of the device.
[0039] The workstations and the conveyer and further components required for operating the apparatus are in this case permanently installed in the transportable enclosure, and this takes place, for example, at the factory on the premises of the manufacturer of the apparatus. In particular, the workstations and the conveyer remain in the enclosure for their entire period of use. Advantageously, the encosure is what is known as an “ISO container” designed according to standard ISO 668. With a view to compact construction, especially what is known as a “20-foot container” of type 1C is preferably used, which container is 20 feet long, 8 feet wide and 8 feet high. Alternatively, a “20-foot container” of type ICC, which is 20 feet long, 8 feet wide and 8 feet 6 inches high, may also be used. An apparatus accommodated in such containers is highly mobile, and can be relocated by land using appropriately equipped transport vehicles, for example, or else can be relocated by air using appropriately equipped transport helicopters.
[0040] In a further refinement, the workstations further comprise at least one of the following workstations:
a heating station designed for preheating a container preform for the subsequent forming of the container which takes place in the container forming station, a temperature testing station designed for testing whether a container preform has a temperature lying in a defined temperature range, a container testing station designed for testing whether a formed container fulfils a number of predefined forming criteria, an irradiation station designed for irradiating a formed container with UV radiation over at least part of its circumference.
[0045] What is achieved by using a heating station, a temperature testing station or a container testing station is that the apparatus operates reliably and can be handled in a simple way. By means of the heating station, the container preforms can be heated in such a way that containers can easily be formed from the container preforms in the container forming station with a low rate of defective. Using the temperature testing station and the container testing station, functional disturbances in individual workstations can be detected and therefore counter measures taken, so that damage and, overall, permanent faults do not occur in other workstations. Thus, using a temperature testing station, on the one hand the functioning of the heating station is monitored and, on the other hand, the thermal properties of each individual container preform are checked. If it is found that the temperature of individual preheated container preforms does not lie in the defined temperature range, these container preforms can be sorted out and removed from the production process. Container preforms which are too cold or too hot may burst in the container forming station and therefore jam the forming station or even damage it. If it is found in the temperature testing station that a relatively large number of successive container preforms do not have the correct temperature, this indicates that there is a fault in the heating station. Counter measures can be taken, for example the entire apparatus can be shut down until the fault in the heating station is rectified. The functioning of the container forming station is monitored by the container testing station. In this case, for example, a check is made as to whether the formed container has a predefined form or whether the formed container has, for example, a hole in a side wall or has even burst. Thus, by means of the container testing station, containers of lower quality, for example incompletely formed containers, are detected and can consequently be separated out. A complete stoppage of the apparatus can thus be avoided. Overall, the heating station and the two testing stations make it possible for the apparatus to be handled in a simple way, so that it can be operated even by persons without much specialized knowledge who are able to rectify operating faults which possibly occur.
[0046] By means of the irradiation station, preferably the neck region of the formed container is irradiated, in particular the threaded region located there. A container preform usually has a thread already, and therefore the neck region of the container preform is not actively heated in the container forming station, in order to avoid damage to the thread. If germs are located in the neck region or in the threaded region, these are not necessarily killed during the heating of the container preform in the container forming station, whereas germs located in the body region of a container preform are killed because of the high temperature inside the container forming station. Germs located in the neck region or threaded region of the formed container can be efficiently killed by irradiation.
[0047] In a further refinement, the conveyer has a return branch.
[0048] The return branch is designed for feeding a container preform, for which a check in the temperature testing station has indicated that the temperature does not lie in the predefined temperature range, to the insertion station. This refinement has the advantage that an insufficiently heated container preform can be fed anew to the production process in an automated way. Simple handling of the apparatus is thereby achieved. Advantageously, the return branch can be utilized also in the event of faults occurring at workstations which follow the temperature testing station in the production process. These are, for example, faults at the container forming station or faults at the filling station.
[0049] Advantageously, the filling station comprises a prefilling station and a finish-filling station. The container can thus be filled in two stages. Using the prefilling station, a container is filled with a first volume of fluid under higher pressure or with a higher volume flow and therefore quickly. By means of the finish-filling station, the container is filled with a second volume of the fluid under lower pressure or with a lower volume flow and therefore slowly. Preferably, the first volume is greater than the second volume. Advantageously, the first volume corresponds to 80% of the overall volume of the fluid with which the container is to be filled. The second volume consequently corresponds to 20% of the overall volume. By virtue of this refinement, particularly during filling with liquids, foaming is prevented, thus ensuring that the apparatus is simple to handle.
[0050] Preferably, the closing station comprises a lid station and a fastening station, the lid station being designed for placing a lid onto the filled container, and the fastening station being designed for releasably fastening the placed-on lid to the container. The functional division into a lid station and a fastening station makes it possible to use stations which are designed especially for their respective function, thus contributing to a reliable operation of the device. The lid may be configured in many different forms. Thus, it may be a screw lid, a crown cork or a stopper cork to be pressed merely into the neck region of the container. Advantageously, the fastening station is designed, furthermore, for providing the filled container with a label. For this purpose, the fastening station may have a stamp, by means of which self-adhesive labels, for example, are pressed onto the filled container.
[0051] Advantageously, the enclosure employed for the mobile use of the apparatus is equipped with a cooling apparatus. Thus, even under adverse conditions of use, high process stability and therefore reliable operation of the apparatus can be ensured. Furthermore, the enclosure is advantageously equipped with an independent energy supply unit. It is thus possible to operate the novel apparatus on the spot in the region of action independently of the prevailing conditions. Preferably, the energy supply unit is operated with diesel fuel, such as is also used in land transport for the motor vehicles required for transport.
[0052] The fluid to be filled using the apparatus is, for example, a gas or a liquid. In the case of a liquid, it may be treated drinking water, refreshing beverages or juices. The container preform and therefore the container formed from the preform are preferably composed of PET (polyethyleneterephthalate), a thermoplastic from the family of polyesters which is produced by polycondensation. Using the novel apparatus, bottles, in particular PET bottles, may be advantageously formed and filled. These bottles may have a capacity volume of 0.5 liters, 1 liter, 1.5 liters or 2 liters. The novel apparatus is in this case designed for a throughput of up to 30 000 PET bottles per day.
[0053] It will be appreciated that the features mentioned above and those yet to be explained below can be used not only in the combinations specified in each case, but also in other combinations or alone, without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] Exemplary embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. In the drawings:
[0055] FIG. 1 shows a simplified illustration of an apparatus for automatically forming and filling containers according to a first exemplary embodiment;
[0056] FIG. 2 shows a simplified illustration of an insertion station used in the apparatus;
[0057] FIG. 3 shows a simplified illustration of a number of container carriers used in the conveyer;
[0058] FIG. 4 shows a detail of a container carrier;
[0059] FIG. 5 shows a sectional illustration of a container carrier with a container inserted therein;
[0060] FIG. 6 shows a simplified illustration of a spring element arranged in the container carrier;
[0061] FIG. 7 shows a sectional illustration of a container carrier with a container prefoi in inserted therein, located in the region of the heating station;
[0062] FIG. 8 shows a sectional illustration of a container carrier with a container inserted therein, located in the region of the container forming station;
[0063] FIG. 9 shows a sectional illustration of a container carrier with a container inserted therein, located in the region of the filling station; and
[0064] FIG. 10 shows a diagrammatic illustration of the apparatus for automatically forming and filling containers according to a second exemplary embodiment.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0065] In FIG. 1 , an apparatus for automatically forming and filling containers is designated as a whole by reference numeral 10 .
[0066] The apparatus 10 has a plurality of workstations 12 and a conveyer 14 . The workstations 12 include an insertion station 16 , a heating station 18 , a temperature testing station 20 , a container forming station 22 , a container testing station 24 , an irradiation station 26 , a filling station 28 , a closing station 30 and an ejection station 32 . The conveyer 14 has a number of container carriers, one of which is designated by way of example by reference numeral 34 in FIG. 1 . Furthermore, the conveyer 14 has a number of movement units moving the container carriers 34 . These are a first movement unit 36 , a second movement unit 38 , a third movement unit 40 and a fourth movement unit 42 . By means of the conveyer 14 , a container preform and a container formed from the preform are moved between the individual workstations 12 . For this purpose, a container carrier 34 is moved from the insertion station 16 via the heating station 18 , the temperature testing station 20 , the container forming station 22 , the container testing station 24 , the irradiation station 26 , the filling station 28 and the closing station 30 to the ejection station 32 . It is then moved from the ejection station 32 to the insertion station 16 again. During this entire movement sequence and the associated processing flow, the container preform and the container formed from the preform reside in a defined container carrier 34 , namely in that carrier into which the container preform is inserted in the insertion station 16 .
[0067] As may be gathered from the illustration in FIG. 1 , an individual container carrier 34 moves on a closed trajectory composed of a plurality of movement segments. By means of the first movement unit 36 , the container carrier 34 is moved along a first movement direction 44 , specifically from the insertion station 16 via the heating station 18 toward the temperature testing station 20 in the present case. By means of the second movement unit 38 , the container carrier 34 is moved along a second movement direction 46 , the second movement direction 46 being oriented essentially orthogonally to the first movement direction 44 . In this case, the container carrier 34 is moved from the temperature testing station 20 via the container forming station 22 toward the container testing station 24 . By means of the third movement unit 40 , the container carrier 34 is moved along a third movement direction 48 , the third movement direction 48 being oriented essentially orthogonally to the second movement direction 46 . The container carrier 34 is in this case moved from the container testing station 24 via the irradiation station 26 and the filling station 28 toward the closing station 30 . By means of the fourth movement unit 42 , the container carrier 34 is moved along a fourth movement direction 50 , the fourth movement direction 50 being oriented essentially orthogonally to the third movement direction 48 . The container carrier 34 is in this case moved from the closing station 30 to the ejection station 32 .
[0068] The movement units 36 , 38 , 40 , 42 are designed such that the container carrier 34 is moved in translational motion. Preferably, the movement units 36 , 38 , 40 , 42 are electric drives in the form of servomotors. The individual container carrier 34 advances linearly on a closed trajectory. More precisely, it is displaced in translational motion along a trajectory. In this case, the container carrier 34 moves within a movement plane which is oriented essentially parallel to a plane defined by ground 52 on which the workstations 12 and the conveyer 14 are mounted.
[0069] An alternative configuration of the conveyer and therefore of the apparatus may also be envisaged, in which the container carrier does not move within a single movement plane, but within a plurality of movement planes which are oriented essentially parallel to one another. That is to say, the conveyer is designed such that the container carrier can not only be moved horizontally, but also such that it experiences a height change from a first movement plane toward a second movement plane. With this alternative, restrictions in the available construction height, such as may occur when the workstations and conveyer are accommodated in a container, can be compensated. A height change of the container carrier can be implemented in that the conveyer has rising and/or falling portions. Thus, for example, it may be advantageous if the container carriers are located, in the region of the insertion station, very far below, that is to say in a movement plane of a short distance from the bottom of the container, for example in order to facilitate gravity-induced insertion of the container preforms into the container carriers. Whereas, in the region of the container forming station, the container carriers may be located in a movement plane which is at a greater distance from the bottom of the container than that movement plane in the region of the insertion station.
[0070] In the present case, the container carriers 34 each have two pick-up regions 54 , 54 ′ for picking up two container preforms or two containers formed from the preforms. This should not be construed in a limiting manner. If the workstations have an appropriate configuration, the container carriers 34 may also have fewer or more than two pick-up regions. The hatching of the pick-up region 54 is intended to make it clear that the container carrier 34 maintains its orientation during the closed-loop movement. The closed-loop movement is composed only of translational movement sections and does not comprise any revolutionary movement sections here.
[0071] The container carriers 34 are moved in a clocked manner, this being described below, starting with a container carrier designated by reference numeral 56 . The container carrier 56 is located in the insertion station 16 . After the insertion of two container preforms, the container carrier 56 is moved along the first movement direction 44 to the left by the amount of one position. The container carrier designated by reference numeral 34 is thereby displaced into the temperature testing station 20 , as indicated by a container carrier 58 illustrated by dashes. By means of the second movement unit 38 , the container carrier 58 is displaced, in a first stroke, first from the temperature testing station 20 into the container forming station 22 and, in a second stroke, then from the container forming station 22 into the container testing station 24 , in each case along the second movement direction 46 . As soon as the container carrier 58 has left the temperature testing station 20 , a further container carrier 56 located in the insertion station 16 can be displaced along the first movement direction 44 toward the temperature testing station 20 by means of the first movement unit 36 . By means of the third movement unit 40 , the container carrier 58 ′ located in the container testing station 24 is displaced to the right along the third movement direction 48 by the amount of one position. The container carrier 60 located in the filling station 28 is thereby displaced into the closing station 30 , as indicated by a container carrier 60 ′ illustrated by dashes. As soon as the container carrier 58 ′ has left the container testing station 24 , the container carrier located in the container forming station 22 can be displaced into the container testing station 24 by means of the second movement unit 38 .
[0072] As may be seen from the illustration in FIG. 1 , the individual workstations 12 are designed differently with regard to the number of simultaneously processable container preforms and containers. Two container preforms can be processed simultaneously using the insertion station 16 , the temperature testing station 20 and the container forming station 22 . Two containers can be processed simultaneously in the container testing station 24 and the filling station 28 . By contrast, only one container can be processed in each case both by the closing station 30 and by the ejection station 32 . Consequently, both in the closing station 30 and in the ejection station 32 , the processing of the containers must take place at double the clock rate, as compared with the other workstations. The container arranged in the pick-up region 54 is processed first in the closing station 30 and then the container arranged in the pick-up region 54 ′. The same applies correspondingly to the ejection station 32 . The closing station 30 has a lid station 62 and a fastening station 64 . As soon as the container carrier 60 ′ has left the lid station 62 , the next container carrier 60 is pushed up into the closing station 30 using the third movement unit 40 . The container carrier 60 ′ is displaced along the fourth movement direction 50 via the ejection station 32 toward the insertion station 16 by means of the fourth movement unit 42 .
[0073] As already explained above, using the insertion station 16 , a container preform is extracted from a bin 66 and, by being inserted into a defined container carrier 56 , is assigned to the latter. By means of the heating station 18 , the container preforms inserted in the container carriers 34 are preheated for the forming of the containers which takes place in the container forming station 22 and which is carried out at a predefined temperature. For this purpose, heating elements, not illustrated, are mounted in the heating station 18 along the first movement direction 44 . In order to achieve uniform heating of the container preforms, these are turned on their way through the heating station 18 . In the temperature testing station 20 , a check is made as to whether a container preform has a temperature lying in a defined temperature range. The temperature range in this case defines those temperatures which are optimal for the forming which takes place in the container forming station 22 . If the temperature of the preheated container preform does not lie in the defined temperature range, the container preform is separated out in the temperature testing station 20 . A container is formed from the container preform in the container forming station 22 , for example by the stretch blow molding method. In this case, the container preform is located in a finish-blowing mold which predetermines the form of the container. In this case, compressed air is first blown onto the container preform, a mandrel is then introduced into the container preform and this is stretched, and thereafter the container preform is finish-blown out by means of compressed air. In the container testing station 24 , a check is made as to whether the container formed in the container forming station 22 fulfills a number of defined forming criteria. In this case, for example, a check is made as to whether the container is formed in the proper way, that is to say has a defined form. Also, a check can be made as to whether the formed container has a hole in its sidewall or in its bottom. If the formed container does not fulfill one of the forming criteria, it is separated out in the container testing station 24 . Separating out, which takes place in each case in the temperature testing station 20 and in the container testing station 24 , can avoid damage in the individual workstations 12 and therefore permanent faults.
[0074] In the irradiation station 26 , the formed container is irradiated with UV radiation at least over part of its circumference. Preferably, the formed container is irradiated in its neck region, in order to kill germs possibly located there. This step is carried out since the neck region of the container preform and of the container formed from the preform is not exposed to the temperatures in the container forming station 22 , as is the case with regard to the body region of the container. On account of the high temperatures prevailing in the container forming station 22 , germs possibly located in the body region of the container have already been killed.
[0075] In the filling station 28 , the formed container is filled with a fluid located in a fluid vessel 68 . The fluid may be a gas or a liquid. Preferably, it is treated drinking water. Advantageously, the filling station 28 is of two-stage construction and is composed of a prefilling station 70 and of a finish-filling station 72 . By means of the prefilling station 70 , a first volume of the fluid is introduced under higher pressure into the container. By means of the finish-filling station 72 , a second volume having a lower pressure is introduced into the container. Preferably, the first volume amounts to 80% of the final volume and the second volume to 20% of the final volume. However, another division between these two volumes may also be envisaged. Instead of the two-stage construction, it is also conceivable for the filling station to have an only single-stage construction.
[0076] By means of the lid station 62 , a lid is placed onto the filled container. This is then releasably fastened to the container by means of the fastening station 64 . Preferably, the lid is designed as a screw lid and the fastening station 64 as a screw station. Advantageously, the lid station 64 is also designed for applying a label to the filled container. By means of the ejection station 32 , the closed container is ejected from the container carrier 34 . This may take place actively, for example by means of a ram acting upon the container from above. Alternatively, this may take place passively if the container carrier 34 is designed such that the filled container falls out of it downward by itself due to gravity.
[0077] With a view to a complete production process which commences with the forming of a container from a container preform and extends via the filling of the container up to the ejection of the container, the apparatus 10 comprises at least one insertion station 16 , one container forming station 22 , one filling station 28 , one closing station 30 and one ejection station 32 .
[0078] For mobile use of the apparatus 10 , the workstations 12 and the conveyer 14 are arranged stationarily in an enclosure 74 . This enclosure 74 is preferably designed as a 20-foot container and is accessible on foot, as indicated by open doors 76 , 76 ′. In order to ensure optimal process stability, a cooling unit 78 is arranged in the enclosure 74 . The illustration of an energy supply unit, by means of which the workstations 12 and the conveyer 14 are supplied with energy, has been dispensed with in FIG. 1 .
[0079] The simplified illustration in FIG. 1 is not intended to have any restrictive effect in terms of an actual structural configuration of the apparatus or of individual components thereof This also applies particularly to the number of container preforms and containers which can be processed in the individual workstations. Thus, workstations may be used which are modified in relation to the workstations illustrated and by means of which a different number of container preforms or containers can be processed. Also, a plurality of examples of one type of workstation may be used in parallel. For example, it is conceivable to use a plurality of container forming stations together in parallel, a correspondingly modified heating station and, if appropriate, a plurality of filling stations being employed. Modified lid stations, fastening stations and filling stations may also be employed correspondingly. The apparatus may be configured individually, depending on the required clock cycle time of the individual production steps or work steps to be carried out at the workstations.
[0080] FIG. 2 illustrates the insertion station 16 . The insertion station 16 comprises a transport unit 90 , a funnel element 92 and a conveying section 94 in the present case. The bin 66 contains a number of container preforms 96 . The container preforms 96 are conveyed into the funnel element 92 via the transport unit 90 . For this purpose, the transport unit 90 is designed, for example, as a rotating conveyor belt with driving projections, one of which is designated by way of example by reference numeral 98 .
[0081] As indicated in FIG. 2 , the container preform 96 has a collar 100 which subdivides the container preform 96 into a neck region 102 and a body region 104 . On account of the gravity acting upon the container preform 96 , the container preform 96 is oriented in the funnel element 92 such that it leaves the funnel element 92 with the body region 104 in front. After leaving the funnel element 92 , the container preform 96 is suspended automatically in the conveying section 94 . The conveying section 94 is preferably composed of two rails 106 , 106 ′ which run in parallel and which, starting from the funnel element 92 , are directed downward toward the container carrier 34 to be loaded. The container preform 96 is supported with its collar 100 on the two rails 106 , 106 ′, its body region 104 pointing downward in the direction of the container carrier 34 . The container preform thus hangs vertically between the rails 106 , 106 ′ arranged on the left and right of it. Via the conveying section 94 , the container preform 96 is fed to the container carrier 34 and inserted into the pick-up region 54 of the latter. On the left next to the container carrier 34 to be loaded, an already loaded container carrier 34 ′ is illustrated, in the pick-up region 54 ′ of which a container preform 96 ′ is inserted. The insertion station 16 is designed such that container preforms can be inserted into both pick-up regions 54 , 54 ′ of the container carrier 34 . For this purpose, the insertion station 16 has, for example, a second conveying section 94 ′, not illustrated in FIG. 2 . Alternatively, the funnel 92 may be designed pivotably, so that container preforms can be alternately inserted into the two pick-up regions 54 , 54 ′. The illustration of a corresponding pivoting mechanism has been dispensed with in FIG. 2 .
[0082] Using the insertion station 16 , the container preforms 96 located in the bin 66 are singled out. The conveying section 94 may be equipped with a separating element, by means of which container preforms 96 which have built up in the conveying section 94 are separated from one another for insertion into the container carrier 34 and are thus admitted singly in the direction of the container carrier 34 to be loaded. By means of the insertion station 16 , the container preforms 96 are inserted into the container carrier 34 from above as a result of a gravity-induced movement. As soon as container preforms 96 are inserted in both pick-up regions 54 , 54 ′ of the container carrier 34 , the latter is displaced in the direction of the heating station 18 and temperature testing station 20 . For this purpose, the container carrier 34 located on a guide stand 108 is displaced by means of the first movement unit 36 . As indicated in FIG. 2 , the container carriers 34 are displaced on a guide stand 108 along all the movement directions 44 , 46 , 48 , 50 . In order to prevent the container carriers 34 from falling down laterally, the guide stand 108 is equipped with lateral guide rails, not illustrated.
[0083] FIG. 3 illustrates in more detailed form the container carriers arranged between the insertion station 16 and the temperature testing station 20 , one of these container carriers being designated by way of example by reference numeral 34 . Each of the container carriers 34 has two gearwheels 120 , 120 ′ which are in each case arranged concentrically to one of the two pick-up regions 54 , 54 ′. The gearwheel 120 engages into a toothing element 122 and the gearwheel 120 ′ engages into a toothing element 122 ′. The two toothing elements 122 , 122 ′ are arranged laterally on a guide stand 108 which cannot be seen in FIG. 3 on account of the type of illustration. The cooperation of the gearwheels 120 , 120 ′ with the respective toothing element 122 , 122 ′ gives rise, during the movement of the container carrier 34 , to rotation of the respective gearwheel 120 , 120 ′ and therefore also of the container preform 96 , 96 ′ arranged in the respective pick-up region 54 , 54 ′. As a result, during the movement of the container carrier 34 along the first movement direction 44 , i.e., during its movement through the heating station 18 , permanent rotation of the container preform 96 is achieved, thus leading to the uniform heating of the latter. The rotational movement which the container preform 96 in this case executes with respect to the container carrier 34 does not constitute a relative movement in the sense of a hand-over movement or grip-around movement. The two toothing elements 122 , 122 ′ may be designed, for example, as rigid racks or as flexible revolving toothed belts. In the case of racks, the container preform 96 , 96 ′ is rotated on account of a relative movement which occurs between the gearwheel 120 , 120 ′ and the respective rack during the movement of the container carrier 34 . In the case of toothed belts, the container preform 96 , 96 ′ can be rotated additionally as a result of the revolving of the toothed belts, with the result that more uniform heating of container preform 96 , 96 ′ is possible. The container preforms 96 , 96 ′ can be moved even when the container carrier 34 itself does not execute any movement. An illustration of the heating station 18 has been dispensed with in FIG. 3 . On account of the higher reliability, the two toothing elements 122 , 122 ′ are preferably designed as racks.
[0084] FIG. 4 shows a detail 130 of the container carrier 34 . The detail 130 shows the cooperation of gearwheel teeth 132 of the gearwheel 120 ′ with toothing element teeth 134 of the toothing element 122 ′. The container preform and the container are thus mounted rotatably in the container carrier.
[0085] FIG. 5 shows a sectional illustration of a container 140 which is inserted in a pick-up region 54 of a container carrier 34 . The container 140 has in its neck region 102 a collar 100 with which it lies on a spring element 142 . The spring element 142 is fastened to a mounting element 146 of the container carrier 34 via fastening elements 144 , 144 ′. Preferably, the spring element 142 is releasably fastened, so that it can be exchanged, as required. The gearwheel 120 is also fastened on the mounting element 146 . The spring element 142 is designed such that, on the one hand, a container preform 96 inserted into the spring element 142 from above is held. On the other hand, the spring element 142 makes it possible to extract a filled and subsequently closed container 140 downward. In this case, the spring element 142 is preferably dimensioned such that a filled container 140 can fall out downward by itself due to gravity. For the sake of clarity, an illustration of a thread in the neck region 102 of the container 140 has been dispensed with in FIG. 5 .
[0086] FIG. 6 illustrates the spring element 142 . This is a thin annular disk with an inner edge 150 and with an outer edge 152 . The inner edge 150 has in this case a diameter such that both a container preform 96 and a container 140 are held, without too much play, by the spring element 142 by the respective collar 100 being gripped underneath. The disk has a plurality of slots 154 starting at the inner edge 150 and running over part of the ring width 156 toward the outer edge 152 . Overall, the inner edge 150 of the disk is designed such that a container preform 96 inserted from above is held by its collar 100 being gripped underneath, and a filled container 140 can be extracted downward out of the spring element 142 and therefore out of the container carrier 34 . An illustration of holes for the purpose of fastening the spring element 142 to the mounting element 146 by means of fastening elements 144 , 144 ′ has been dispensed with. The illustration of slots 154 running rectilinearly should not be construed in a limiting manner. The slots may have any desired form; for example, they may be of arcuate form.
[0087] FIG. 7 shows a container carrier 34 in an embodiment which is slightly modified, as compared with the illustration in FIG. 5 . A container preform 96 is inserted into the container carrier 34 and is held by a spring element 142 by the collar 100 being gripped underneath. The spring element 142 is fastened to the container carrier 34 via a mounting element 146 . A gearwheel 120 is likewise fastened to the mounting element 146 . The illustration of fastening elements 144 , 144 ′ has been dispensed with. The mounting element 146 is fixed in a longitudinal direction by means of a securing element which is attached in a continuous groove on the mounting element 146 below the container carrier 34 . The longitudinal direction is in this case defined by the axis of rotation of the container preform. The mounting element 146 can easily be exchanged by the securing element being released. The securing element may be, for example, a saw ring.
[0088] The container carrier 34 and therefore the container preform 96 inserted in it are moved along the first movement direction 44 past heating elements 160 arranged in the heating station 18 . The heating elements 160 may in this case be designed, for example, as electrically operated heating bars. In this case, heating bars, the length of which corresponds to the length of the heating station 18 , may be used. It is also conceivable, however, to arrange a plurality of shorter heating bars one behind the other over the entire length of the heating station 18 .
[0089] FIG. 8 illustrates a container 140 which is arranged in a container carrier 34 and is located in the container forming station 22 . The container carrier 34 corresponds in its construction to the container carrier illustrated in FIG. 7 . The container 140 is carried by the spring element 142 by the collar 100 of said container being gripped underneath. In the container forming station 22 , the container 140 is formed from a container preform 96 . This takes place by what is known as a stretch blow-molding method. In this case, in a first step, a small quantity of compressed air is first introduced into the container preform 96 , and in a second step a mandrel is introduced into the container preform 96 in order to stretch the latter. Then, finally, in a third step, a large quantity of compressed air is introduced into the stretched container preform and the latter is finish-blown out to form the container 140 . FIG. 8 shows the finish-blown-out container 140 which is still located in a finish-blowing mold 170 which is composed of two mold halves 172 , 172 ′. Preferably, the two mold halves 172 , 172 ′ are designed to be heatable. A feed is designated by reference numeral 174 . Via this feed 174 , on the one hand, compressed air is introduced into the container prefotin 96 . On the other hand, via this feed 174 , the mandrel for stretching the container preform 96 is also introduced.
[0090] The two mold halves 172 , 172 ′ are designed to be movable. They can be moved in each case horizontally, specifically transversely with respect to the direction of advance of the container preform or containers. During the advancing movement of the container prefotins into the container forming station and during the advancing movement of the containers out of the container forming station, the two mold halves 172 , 172 ′ are arranged in an open position and thus open the way for the container preforms or containers.
[0091] FIG. 9 shows a container 140 which is inserted into a container carrier 34 and is located in the filling station 28 . The container carrier 34 corresponds in its construction to the container carriers which are illustrated in FIGS. 7 and 8 . In the filling station 28 , a fluid is introduced into the container 140 via a filler piece 180 . The illustration in FIG. 9 in this case leaves undecided whether the container 140 is in the prefilling station 70 or in the finish-filling station 72 .
[0092] As already stated above, the ejection station 32 and consequently also the spring element 142 may be designed according to two different approaches. According to a first approach, the ejection station 32 is designed as a passive ejection station. In this case, the spring element 142 is dimensioned such that the filled container 140 in the ejection station 32 falls out of the container carrier 34 downward by itself due to gravity. That is to say, the filled container 140 does not have to be acted upon actively in the ejection station 32 in order to extract it from the container carrier 34 . In this case, starting with the filling station 28 , a guide plate 182 is to be provided which is arranged below the container 140 to be filled, so that, after the end of the filling operation, the container 140 does not fall out of the container carrier 34 downward by itself due to gravity as early as in the filling station 28 . The guide plate 182 extends from the filling station 28 via the closing station 30 as far as the ejection station 32 . According to a second approach, the ejection station 32 is designed as an active ejection station. In this case, the spring element 142 does not have to be dimensioned such that the filled container 140 falls out of the container carrier 34 downward by itself due to gravity. Instead, the container 140 is acted upon actively in the ejection station 32 , for example by means of a ram, in order to press said container downward out of the spring element 142 and therefore out of the container carrier 34 by the application of force. In this case, said guide plate 182 may be dispensed with.
[0093] FIG. 10 illustrates an apparatus 10 ′ for automatically forming and filling containers according to a second exemplary embodiment.
[0094] The apparatus 10 ′ illustrated in FIG. 10 differs from the apparatus 10 illustrated in FIG. 1 in that the apparatus 10 ′ additionally has a return branch 190 . By means of the return branch 190 , a container preform 96 for which it has been found in the temperature testing station 20 ′ that its temperature does not lie in the defined temperature range can be fed to the insertion station 16 ′. For this purpose, the conveyer 14 ′ comprises a fifth movement unit 192 , by means of which a container carrier 34 can be moved along a fifth movement direction 194 . The fifth movement direction 194 is in this case oriented essentially orthogonally to the first movement direction 44 and antiparallel to the second movement direction 46 . Furthermore, the conveyer 14 ′ comprises a sixth movement unit 196 , by means of which a container carrier 34 can be moved along a sixth movement direction 198 , the sixth movement direction 198 being oriented essentially orthogonally to the fifth movement direction 194 . Furthermore, the conveyer 14 ′ has a seventh movement unit 200 , by means of which a container carrier 34 can be moved along a seventh movement direction 202 , the seventh movement direction 202 being oriented essentially orthogonally to the sixth movement direction 198 .
[0095] By means of the movement units 192 , 196 , 200 , a container carrier 34 can be moved from the temperature testing station 20 ′ via an ejection station 204 toward the insertion station 16 ′. In the ejection station 204 , a container preform 96 which is located in the container carrier 34 and the temperature of which does not lie in the defined temperature range is removed from the container carrier 34 . In this case, in the event that the container preform 96 has not been damaged on account of incorrect heating, it is conceivable to feed said container preform to the production process anew and thus introduce it into the bin 66 . Preferably, this also takes place via the return branch 190 in the case of faults in the container forming station 20 ′ or in the case of faults in the filling station 28 .
[0096] Components which are illustrated in FIG. 10 and correspond in construction and function to a component illustrated in FIG. 1 are identified by the same reference numerals and are therefore not described in any more detail. Instead, reference is made to the statements relating to FIG. 1 .
[0097] Contrary to the illustration in FIG. 10 , it is conceivable to provide, instead of an independent second movement unit 38 and an independent fifth movement unit 192 , a single movement unit which enables a container carrier 34 to execute both movement in the second movement direction 46 and movement in the fifth movement direction 194 . The same applies correspondingly to the fourth movement unit 42 and to the seventh movement unit 200 . Furthermore, an alternative construction of the return branch 190 may be envisaged. The alternative return is of arcuate form. Preferably, the container carriers in the return branch 190 move on a semicircular trajectory. Alternatively, the trajectory may be composed of two quarter circle paths which are connected to one another via a straight path segment. The arcuately formed return branch 190 has the advantage that only one movement unit is required instead of three. Moreover, fewer container carriers are required for the return.
[0098] For the devices illustrated in FIG. 1 and FIG. 10 , the control procedure is presented as follows: insertion of a container preform, heating of the container preform, stretch blow-molding of the container preform into a container, filling of the container, closing of the container, labeling of the container and ejection of the labeled and closed container.
[0099] For the apparatus 10 , if there is a fault found in the temperature testing station 20 , the operating procedure is presented as follows: the container preform found to be faulty is separated out directly, without return, at the temperature testing station 20 . In the case of the apparatus 10 ′, the container preform found to be faulty, although also being separated out in the temperature testing station 20 ′, is fed via the return branch to an ejection station 32 , whereby it is possible, where appropriate, to feed this container preform to the production process again by insertion in the insertion station 16 ′.
[0100] If a fault is detected in the container testing station 24 , both in the case of the apparatus 10 and in the case of the apparatus 10 ′ the container found to be faulty is separated out directly, without return, at the container testing station 24 . Moreover, it is stored in a memory which container carrier is moved further on without a container, so that the execution of work steps at the following workstations can be avoided.
[0101] Using the novel apparatus, bottles can be picked up at a defined position, which is independent from the bottle production process, namely the collar located in the neck region, in a bottle carrier and can be guided through the complete plant for bottle production and bottle filling. Within complete bottle production and filling, there is no need for any hand-over stations, with the exception of the insertion station and ejection station. The apparatus is thus designed to be gripper-free. Faulty bottles produced in the bottle blowing station can be detected and separated out. These therefore do not cause a stoppage of the plant. Overall, operating faults in the region of the bottle blowing station or in the region of the bottle filling station do not lead to faults or damage in another plant part.
[0102] It may be noted at this occasion that the illustration which is partially simplified in the figures should not be construed in a limiting manner with respect to the actual structural configuration of individual components installed in the device, such as, for example, individual workstations or the conveyer or components thereof. Also, illustrating one and the same component sometimes in a different size in the figures is not intended to have any restrictive effect. | An apparatus and method for automatically forming and filling containers, such as water bottles. The apparatus has a plurality of workstations and a conveyer comprising container carriers. The workstations comprise an insertion station, a container foiming station, a filling station, a closing station, and an ejection station. The insertion station feeds a container preform into a container carrier. The container forming station forms a container from the container preform. The filling station fills the formed container with a fluid. The closing station closes the filled container with a lid. The conveyer moves the container preform and the container from the insertion station via the container forming station, the filling station and the closing station to the ejection station. The container preform and the container formed from the preform may continuously reside in the container carrier along the whole process beginning with the insertion station and ending with the ejection station. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a coding and decoding technique for transmitting speech signals at a low bit rate, and more particularly to a decoding method and a decoding apparatus for improving sound quality in an environment where noise exists.
2. Description of the Prior Art
Methods of coding a speech signal by separating the speech signal to a linear prediction filter and its driving excitation signal (also referred to as excitation signal or excitation vector) are widely used as a method of efficiently coding a speech signal at an intermediate or low bit rate. One typical method thereof is CELP (Code Excited Linear Prediction). In the CELP, an excitation signal (excitation vector) drives a linear prediction filter for which a linear prediction coefficient representing frequency characteristics of input speech is set, thereby obtaining a synthesized speech signal (reproduced speech, reproduced vector). The excitation signal is represented by the sum of a pitch signal (pitch vector) representing a pitch period of speech and a sound source signal (sound source vector) comprising random numbers or pulses. In this case, each of the pitch signal and the sound source signal is multiplied by gain (i.e., pitch gain and sound source gain). For the CELP, reference can be made to M. Schroeder et al., “Code excited linear prediction: High quality speech at very low bit rates”, Proc. of IEEE Int. Conf. on Acoust., Speech and Signal processing, pp. 937–940, 1985 (Literature 1).
Mobile communication systems such as a cellular phone system require favorable quality of speech in noisy environments typified by the hustle and bustle in downtown or the inside of a running car. However, speech coding techniques based on the CELP have a problem of significant deterioration of sound quality for speech on which noise is superimposed, that is, speech with background noise. A time period in a speech signal under a noisy environment is referred to as a noise period.
For improving the quality of coded speech from the speech with background noise, a method of smoothing the sound source gain at a decoder has been proposed. In this method, the smoothing of the sound source gain causes a smooth change with time in short time average power of the sound source signal multiplied by the sound source gain, resulting in a smoothed change with time in short time average power of the excitation signal as well. This leads to mitigation of significant variations in short time average power in decoded noise, which is one of factors for degradation, thereby improving the sound quality.
For a method of smoothing gain in the sound source signal, reference can be made, for example, to Section 6.1 of “Digital Cellular Telecommunication System; Adaptive Multi-Rate Speech Transcoding”, ETSI Technical Report, GSM 06.90, version 2.0.0 (Literature 2).
FIG. 1 is a block diagram showing an example of a configuration of a conventional speech signal decoding apparatus, and illustrates a technique of improving quality of coding of a speech with background noise by smoothing gain in a sound source signal. Assume herein that bit sequences are inputted at a frame period of T fr (for example, 20 milliseconds), and reproduced vectors are calculated at a subframe period of (T fr /N sfr ) (for example, 5 milliseconds) where N sfr is an integer number (for example, 4). A frame length is L fr samples (for example, 320 samples), and a subframe length is L sfr samples (for example, 80 samples). These numbers of samples are employed in the case of a sampling frequency of 16 kHz for input signals. Description is hereinafter made for the speech signal decoding apparatus shown in FIG. 1 .
Bit sequences of coded data are supplied from input terminal 10 . Code input circuit 1010 divides and converts the bit sequences supplied from input terminal 10 to indexes corresponding to a plurality of decoding parameters. Code input circuit 1010 provides an index corresponding to an LSP (Line Spectrum Pair) representing the frequency characteristic of the input signal to LSP decoding circuit 1020 , an index corresponding to delay representing the pitch period of the input signal to pitch signal decoding circuit 1210 , an index corresponding to a sound source vector including random numbers or pulses to sound source signal decoding circuit 1110 , an index corresponding to a first gain to first gain decoding circuit 1220 , and an index corresponding to a second gain to second gain decoding circuit 1120 .
LSP decoding circuit 1020 contains a table in which plural sets of LSPs are stored. LSP decoding circuit 1020 receives, as its input, the index outputted from code input circuit 1010 , reads the LSP corresponding to that index from the table contained therein, and sets the read LSP to LSP: {circumflex over (q)} j (N sfr ) (n), j=1, . . . , N p in N sfr th subframe of the current frame (n-th frame), where N p represents a linear prediction order. The LSPs from the first to (N sfr −1)th subframes are derived by linear interpolation of {circumflex over (q)} j (N sfr ) (n) and {circumflex over (q)} j (N sfr ) (n−1). LSP decoding circuit 1020 outputs the LSP: {circumflex over (q)} j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr to linear prediction coefficient converting circuit 1030 and to smoothing coefficient calculating circuit 1310 .
Linear prediction coefficient converting circuit 1030 converts the LSP: {circumflex over (q)} j (m) (n) supplied from LSP decoding circuit 1020 to linear prediction coefficient {circumflex over (α)} j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr , and outputs it to synthesizing filter 1040 . It should be noted that, for the conversion from the LSP to the linear prediction coefficient, known methods can be used, for example the method described in Section 5.2.4 of Literature 2.
Sound source signal decoding circuit 1110 contains a table in which a plurality of sound source vectors are stored. Sound source signal decoding circuit 1110 receives the index outputted from code input circuit 1010 , reads the sound source vector corresponding to that index from the table contained therein, and outputs it to second gain circuit 1130 .
First gain decoding circuit 1220 includes a table in which a plurality of gains are stored. First gain decoding circuit 1220 receives, as its input, the index outputted from code input circuit 1010 , reads the first gain corresponding to that index from the table contained therein, and outputs it to first gain circuit 1230 .
Second gain decoding circuit 1120 contains another table in which a plurality of gains are stored. Second gain decoding circuit 1120 receives, as its input, the index from code input circuit 1010 , reads the second gain corresponding to that index from the table contained therein, and outputs it to smoothing circuit 1320 .
First gain circuit 1230 receives, as its inputs, a first pitch vector, later described, outputted from pitch signal decoding circuit 1210 and the first gain outputted from first gain decoding circuit 1220 , multiplies the first pitch vector by the first gain to produce a second pitch vector, and outputs the produced second pitch vector to adder 1050 .
Second gain circuit 1130 receives, as its inputs, the first sound source vector from sound source signal decoding circuit 1110 and the second gain, later described, from smoothing circuit 1320 , multiplies the first sound source vector by the second gain to produce a second sound source vector, and outputs the produced second sound source vector to adder 1050 .
Adder 1050 calculates the sum of the second pitch vector from first gain circuit 1230 and the second sound source vector from second gain circuit 1130 and outputs the result of the addition to synthesizing filter 1040 as an excitation vector.
Storage circuit 1240 receives the excitation vector from adder 1050 and holds it. Storage circuit 1240 outputs the excitation vectors which were previously received and held thereby to pitch signal decoding circuit 1210 .
Pitch signal decoding circuit 1210 receives, as its inputs, the previous excitation vectors held in storage circuit 1240 and the index from code input circuit 1010 . The index specifies a delay L pd . Pitch signal decoding circuit 1210 takes a vector for L sfr samples corresponding to a vector length from the point going back L pd samples from the beginning of the current frame in the previous excitation vectors to produce a first pitch signal (i.e., first pitch vector). When L pd <L sfr , a vector for L pd samples is taken, and the taken L pd samples are repeatedly connected to produce a first pitch vector with a vector length of L sfr samples. Pitch signal decoding circuit 1210 outputs the first pitch vector to first gain circuit 1230 .
Smoothing coefficient calculating circuit 1310 receives the LSP: {circumflex over (q)} j (m) (n) outputted from LSP decoding circuit 1020 , and calculates an average LSP: {overscore (q)} 0j (n) in n-th frame with the following equation:
{overscore (q)} 0j (n)=0.84·{overscore (q)} 0j (n−1)+0.16·{circumflex over (q)} j (N sfr ) (n)
Next, smoothing coefficient calculating circuit 1310 calculates a variation d 0 (m) of the LSP for each subframe m with the following equation:
d 0 ( m ) = ∑ j = 1 N p q _ 0 j ( n ) - q ^ j ( m ) ( n ) q _ 0 j ( n )
A smoothing coefficient k 0 (m) in subframe m is calculated with the following equation:
k 0 (m)=min(0.25, max(0, d 0 (m)−0.4))/0.25
where min(x,y) is a function which takes on a smaller one of x and y, while max(x,y) is a function which takes on a larger one of x and y. Finally, smoothing coefficient calculating circuit 1310 outputs the smoothing coefficient k 0 (m) to smoothing circuit 1320 .
Smoothing circuit 1320 receives, as its inputs, the smoothing coefficient k 0 (m) from smoothing coefficient calculating circuit 1310 and the second gain from second gain decoding circuit 1120 . Smoothing circuit 1320 calculates an average gain {overscore (g)} 0 (m) from a second gain ĝ 0 (m) in a subframe m with the following equation:
g
_
0
(
m
)
=
1
5
∑
i
=
0
4
g
^
0
(
m
-
i
)
Next, the following equation is substituted for the second gain:
ĝ 0 (m)=ĝ 0 (m)·k 0 (m)+{overscore (g)} 0 (m)·(1−k 0 (m))
Finally, smoothing circuit 1320 outputs the substituted second gain to second gain circuit 1130 .
Synthesizing filter 1040 receives, as its inputs, the excitation vector from adder 1050 and the linear prediction coefficient {circumflex over (α)} j (m) (n), j=1, . . . , N p , m=1, . . . N sfr from linear prediction coefficient converting circuit 1030 . In synthesizing filter 1040 , the excitation vector drives the synthesizing filter (1/A(z)) for which the linear prediction coefficient is set to calculates a reproduced vector which is then outputted from output terminal 20 .
The transfer function of synthesizing filter 1040 is represented as follows:
1 A ( z ) = 1 ( 1 - ∑ i = 1 N p α i z i )
where the linear prediction coefficient is α i , i=1, . . . , N p .
Next, a conventional speech signal coding apparatus is described. FIG. 2 is a block diagram showing an example of a configuration of a speech signal coding apparatus used in a conventional speech signal coding and decoding system. The speech signal coding apparatus is used in a pair with the speech signal decoding apparatus shown in FIG. 1 such that coded data outputted from the speech signal coding apparatus is transmitted and inputted to the speech signal decoding apparatus shown in FIG. 1 . Since the operations of first gain circuit 1230 , second gain circuit 1130 , adder 1050 and storage circuit 1240 in FIG. 2 are similar to those of the respective corresponding functional blocks described for the speech signal decoding apparatus shown in FIG. 1 , the description thereof is not repeated here.
In the apparatus shown in FIG. 2 , speech signals are sampled, and a plurality of the resultant samples are formed into one vector as one frame to produce an input signal (input vector) which is then inputted from input terminal 30 .
Linear prediction coefficient calculating circuit 5510 performs linear prediction analysis on the input vector supplied from input terminal 30 to derive a linear prediction coefficient. For the linear prediction analysis, reference can be made to known methods, for example, in Section 8 “Linear Predictive Coding of Speech” of “Digital Processing of Speech Signals”, L. R. Rabiner et al., Prentice-Hall, 1978 (Literature 3). Linear prediction coefficient calculating circuit 5510 outputs the derived linear prediction coefficient to LSP conversion/quantization circuit 5520 .
LSP conversion/quantization circuit 5520 receives the linear prediction coefficient from linear prediction coefficient calculating circuit 5510 , converts the linear prediction coefficient to an LSP, quantizes the LSP to derive the quantized LSP. For the conversion from the linear prediction coefficient to the LSP, known methods can be referenced, for example, the method described in Section 5.2.4 of Literature 2. For the quantization of the LSP, the method described in Section 5.2.5 of Literature 2 can be referenced. The quantized LSP is set to a quantized LSP:{circumflex over (q)} j (N sfr ) (n), j=1, . . . , N p in N sfr th subframe of the current frame (n-th frame), similarly to the LSP in the LSP decoding circuit of the speech signal decoding apparatus shown in FIG. 1 . The quantized LSPs from the first to (N sfr −1)th subframes are derived by linear interpolation of {circumflex over (q)} j (N sfr ) (n) and {circumflex over (q)} j (N sfr ) (n-1). The LSP is set to an LSP in a (N sfr −1)th subframe of the current frame (n-th frame). The LSPs from the first to (N sfr −1)th subframes are derived by linear interpolation of q j (N sfr ) (n) and q j (N sfr ) (n−1).
LSP conversion/quantization circuit 5520 outputs the LSP: q j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr and the quantized LSP: {circumflex over (q)} j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr to linear prediction coefficient converting circuit 5030 , and outputs the index corresponding to the quantized LSP: {circumflex over (q)} j (N sfr ) (n) to code output circuit 6010 .
Linear prediction coefficient converting circuit 5030 receives, as its inputs, the LSP: q j (M) (n) and the quantized LSP: {circumflex over (q)} (m) (n) from LSP conversion/quantization circuit 5520 , converts the LSP (q j (m) (n)) to a linear prediction coefficient [α j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr ], converts the quantized LSP ({circumflex over (q)} j (m) (n)) to a quantized linear prediction coefficient: {circumflex over (α)} j (m) (n), j=1, . . . , N p , m=1, . . . , N sfr , outputs the linear prediction coefficient α j (m) (n) to weighting filter 5050 and to weighting synthesizing filter 5040 , and outputs the quantized linear prediction coefficient {circumflex over (α)} j (m) (n) to weighting synthesizing filter 5040 . For the conversion from the LSP to the linear prediction coefficient and the conversion from the quantized LSP to the quantized linear prediction coefficient, known methods can be referenced, for example, the method described in Section 5.2.4 of Literature 2.
Weighting filter 5050 receives, at its inputs, the input vector from input terminal 30 and the linear prediction coefficient α j (m) (n) from linear prediction coefficient converting circuit 5030 , uses the linear prediction coefficient to produce a transfer function W(z) of the weighting filter corresponding to human auditory characteristics. The weighting filter is driven by the input vector to obtain a weighted input vector. Weighting filter 5050 outputs the weighted input vector to differentiator 5060 . The transfer function W(z) of the weighting filter is represented as follows:
W ( z )= Q ( Z/γ 1 )/ Q ( Z/γ 2 )
Here, the followings hold:
Q ( z / γ 1 ) = 1 - ∑ i = 1 N p α i ( m ) γ 1 i z i Q ( z / γ 2 ) = 1 - ∑ i = 1 N p α i ( m ) γ 2 i z i
γ 1 and γ 2 are constants, for example, γ 1 =0.9 and γ 2 =0.6. For details on the weighting filter, Literature 1 can be referenced.
Weighting synthesizing filter 5040 receives, as its inputs, an excitation vector outputted from adder 1050 , the linear prediction coefficient α j (m) (n), and the quantized linear prediction coefficient {circumflex over (α)} j (m) (n) outputted from linear prediction coefficient converting circuit 5030 . The weighting synthesizing filter H(z)W(z)=Q(z/γ 1 )/[A(z)Q(z/γ 2 )] for which those are set is driven by the excitation vector to obtain a weighted reproduced vector. The transfer function H(z)=1/A(z) of the synthesizing filter is represented as follows:
1
A
(
z
)
=
1
(
1
-
∑
i
=
1
N
p
α
^
i
(
m
)
z
i
)
Differentiator 5060 receives, as its inputs, the weighted input vector from weighting filter 5050 and the weighted reproduced vector from weighting synthesizing filter 5040 , and calculates and outputs the difference between them as a difference vector to minimization circuit 5070 .
Minimization circuit 5070 sequentially outputs indexes corresponding to all sound source vectors stored in sound source signal producing circuit 5110 to sound source signal producing circuit 5110 , indexes corresponding to all delays L pd within a specified range in pitch signal producing circuit 5210 to pitch signal producing circuit 5210 , indexes corresponding to all first gains stored in first gain producing circuit 6220 to first gain producing circuit 6220 , and indexes corresponding to all second gains stored in second gain producing circuit 6120 to second gain producing circuit 6120 . Minimization circuit 5070 also calculates the norm of the difference vector outputted from differentiator 5060 , selects the sound source vector, delay, first gain and second gain which lead to a minimized norm, and outputs the indexes corresponding to the selected values to code output circuit 6010 .
Each of pitch signal producing circuit 5210 , sound source signal producing circuit 5110 , first gain producing circuit 6220 and second gain producing circuit 6120 sequentially receives the indexes outputted from minimization circuit 5070 . Since each of these pitch signal producing circuit 5210 , sound source signal producing circuit 5110 , first gain producing circuit 6220 and second gain producing circuit 6120 is the same as the counterpart of pitch signal decoding circuit 1210 , sound source signal decoding circuit 1110 , first gain decoding circuit 1220 and second gain decoding circuit 1120 shown in FIG. 1 except the connections for input and output, the detailed description of each of these blocks is not repeated.
Code output circuit 6010 receives the index corresponding to the quantized LSP outputted from LSP conversion/quantization circuit 5520 , receives the indexes each corresponding to the sound source vector, delay, first gain and second gain outputted from minimization circuit 5070 , converts each of the indexes to a code of bit sequences, and outputs it through output terminal 40 .
The aforementioned conventional decoding apparatus and coding and decoding system have a problem of insufficient improvement in degradation of decoded sound quality in a noise period since the smoothing of the sound source gain (second gain) in the noise period fails to cause a sufficiently smooth change with time in short time average power calculated from the excitation vector. This is because the smoothing only of the sound source gain does not necessarily sufficiently smooth the short time average power of the excitation vector which is derived by adding the sound source vector (the second sound source vector after the gain multiplication) to a pitch vector (the second pitch vector after the gain multiplication).
FIG. 3 shows short time average power of an excitation signal (excitation vector) when sound source gain smoothing is performed in a noise period on the basis of the aforementioned prior art. FIG. 4 shows short time average power of an excitation signal when such smoothing is not performed. In each of these graphs, the horizontal axis represent a frame number, while the vertical axis represents power. The short time average power is calculated every 80 msec. It can be seen from FIG. 3 and FIG. 4 that, when the sound source gain is smoothed according to the prior art, the short time average power in the excitation signal after the smoothing is not necessarily smoothed sufficiently in terms of time.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a decoding method and a coding and decoding method with improved degradation of decoded sound quality in a noise period.
It is another object of the present invention to provide a decoding apparatus and a coding and decoding system with improved degradation of decoded sound quality in a noise period.
The first object of the present invention is achieved by a method of decoding a speech signal by decoding information on an excitation signal and information on a linear prediction coefficient from a received signal, producing the excitation signal and the linear prediction coefficient from the decoded information, and driving a filter configured with the linear prediction coefficient by the excitation signal, the method comprising the steps of: calculating a norm of the excitation signal for each fixed period; smoothing the calculated norm using a norm obtained in a previous period; changing the amplitude of the excitation signal in the period using the calculated norm and the smoothed norm; and driving the filter by the excitation signal with the changed amplitude.
The second object of the present invention is achieved by an apparatus for decoding a speech signal by decoding information on an excitation signal and information on a linear prediction coefficient from a received signal, producing the excitation signal and the linear prediction coefficient from the decoded information, and driving a filter configured with the linear prediction coefficient by the excitation signal, the apparatus comprising: an excitation signal normalizing circuit for calculating a norm of the excitation signal for each fixed period and dividing the excitation signal by the norm; a smoothing circuit for smoothing the norm using a norm obtained in a previous period; and an excitation signal restoring circuit for multiplying the excitation signal by the smoothed norm to change the amplitude of the excitation signal in the period.
In the present invention, the excitation signal is typically an excitation vector.
In the present invention, since smoothing is performed in a noise period on the norm calculated from the excitation vector obtained by adding a sound source vector (a second sound source vector after gain multiplication) to a pitch vector (a second pitch vector after gain multiplication), short time average power is smoothed in terms of time in the excitation vector. Therefore, improvement can be obtained in degradation of decoded sound quality in a noise period.
In the present invention, the smoothing may be performed on the norm derived from the excitation vector by selectively using a plurality of processing methods provided in consideration of the characteristic of an input signal, not by using single processing. The provided processing methods include, for example, moving average processing which performs calculations from decoding parameters in a limited previous period, auto-regressive processing which can consider the effect of a long past period, or non-linear processing which limits a preset value with upper and lower limits after calculation of an average.
The above and other objects, features, and advantages of the present invention will be apparent from the following description referring to the accompanying drawings which illustrate an example of a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an example of a configuration of a conventional speech signal decoding apparatus;
FIG. 2 is a block diagram showing an example of a configuration of a conventional speech signal coding apparatus;
FIG. 3 is a graph representing short time average power of an excitation signal (excitation vector) for which smoothing of sound source gain was performed on the basis of a conventional method;
FIG. 4 is a graph representing short time average power of an excitation signal (excitation vector) for which smoothing was not performed;
FIG. 5 is a block diagram showing a configuration of a speech signal decoding apparatus based on a first embodiment of the present invention;
FIG. 6 is a graph representing short time average power of an excitation signal (excitation vector) for which smoothing was performed on a norm calculated from an excitation vector based on the present invention;
FIG. 7 is a block diagram showing a configuration of a speech signal decoding apparatus based on a second embodiment of the present invention;
FIG. 8 is a block diagram showing a configuration of a speech signal decoding apparatus based on a third embodiment of the present invention; and
FIG. 9 is a block diagram showing a configuration of a speech signal decoding apparatus based on a fourth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A speech signal decoding apparatus of a first embodiment of the present invention shown in FIG. 5 forms a pair with the conventional speech signal coding apparatus shown in FIG. 2 to constitute a speech signal coding and decoding system, and is configured to receive, as its input, coded data outputted from the speech signal coding apparatus shown in FIG. 2 to perform decoding of the coded data.
The speech signal decoding apparatus shown in FIG. 5 differs from the conventional speech signal decoding apparatus shown in FIG. 1 in that excitation signal normalizing circuit 2510 and excitation signal restoring circuit 2610 are added and the connections are changed in the vicinity of them including adder 1050 and smoothing circuit 1320 . Specifically, the output from adder 1050 is supplied only to excitation signal normalizing circuit 2510 , and the output from second gain decoding circuit 1120 is directly supplied to second gain circuit 1130 , the gain from excitation signal normalizing circuit 2510 is supplied to smoothing circuit 1320 instead of the output from second gain decoding circuit 1120 , the shape vector from excitation signal normalizing circuit 2510 and the output from smoothing circuit 1320 are supplied to excitation signal restoring circuit 2610 , and the output from excitation signal restoring circuit 2610 is supplied to synthesizing filter 1040 and to storage circuit 1240 instead of the output from adder 1050 .
Excitation signal normalizing circuit 2510 calculates a norm of the excitation vector outputted from adder 1050 for each fixed period, and divides the excitation vector by the calculated norm. In this speech signal decoding apparatus, smoothing circuit 1320 smoothes a norm with a norm obtained in a previous period. Excitation signal restoring circuit 2610 multiplies the excitation vector by the smoothed norm to change the amplitude of the excitation vector in that period.
In FIG. 5 , the functional blocks identical to those in FIG. 1 are designated the same reference numerals as those in FIG. 1 . Specifically, since input terminal 10 , output terminal 20 , code input circuit 1010 , LSP decoding circuit 1020 , linear prediction coefficient converting circuit 1030 , sound source signal decoding circuit 1110 , storage circuit 1240 , pitch signal decoding circuit 1210 , first gain decoding circuit 1220 , second gain decoding 1120 , first gain circuit 1230 , second gain circuit 1130 , adder 1050 , smoothing coefficient calculating circuit 1310 and synthesizing filter 1040 in FIG. 5 are the same as the counterparts in FIG. 1 , the description thereof is not repeated here. Description is hereinafter made for excitation signal normalizing circuit 2510 and excitation signal restoring circuit 2610 .
Assume herein, similarly to the case shown in FIG. 1 , that bit sequences are inputted at a frame period of T fr (for example, 20 msec), and reproduced vectors are calculated at a period (subframe) of T fr /N sfr (for example, 5 msec) where N sfr is an integer number (for example, 4). A frame length corresponds to L fr samples (for example, 320 samples), and a subframe length corresponds to L sfr samples (for example, 80 samples). These numbers are employed in the case of a sampling frequency of 16 kHz for input signals.
Excitation signal normalizing circuit 2510 receives, as its input, an excitation vector [x exc (m) (i), i=0, . . . , L sfr −1, m=0, . . . , N sfr −1] in m-th subframe from adder 1050 , calculates gain and a shape vector from the excitation vector [x exc (m) (i)] for each subframe or for each subsubframe obtained by dividing a subframe, outputs the calculated gain to smoothing circuit 1320 and the shape vector to excitation signal restoring circuit 2610 . As the gain, such a norm as represented with the following equation is used:
g exc ( m · N ssfr + l ) = ∑ n = 0 L sfr / N ssfr - 1 x exc ( m ) ( l · L sfr N ssfr + n ) 2 m=0, . . . , N sfr −1, l=0, . . . N ssfr −1
where N ssfr is the number of division of a subframe (the number of subsubframes in a subframe) (for example, two). At this point, excitation signal normalizing circuit 2510 calculates the shape vector obtained by dividing the excitation vector [x exc (m) (i)] by the gain [g exc (j), j=0, . . . , (N sfr ·N ssfr −1)] with the following equation:
s exc ( m · N ssrf + l ) ( i ) = 1 g exc ( m · N ssfr + l ) · x exc ( m ) ( l · L sfr N ssfr + i ) i=0, . . . , L sfr /N ssfr −1, l=0, . . . , N ssfr −1, m=0, . . . , N sfr −1
Excitation signal restoring circuit 2610 receives, as its input, the smoothed gain [{overscore (g)} exc (j), j=0, . . . , (N sfr ·N sfr −1)] from smoothing circuit 1320 and the shape vector [s (exc) (m) (i), i=0, . . . , (L sfr /N ssfr −1), j=0, . . . , (N sfr ·N ssfr −1)] from excitation signal normalizing circuit 2510 , calculates a smoothed excitation vector with the following equation, and outputs the excitation vector to storage circuit 1240 and to synthesizing filter 1040 :
x ^ exc ( m ) ( l · L sfr N ssfr + i ) = g _ exc ( m · N ssfr + 1 ) · s exc ( m · N ssfr + l ) ( i ) i=0, . . . , L sfr /N ssfr −1, l=0, . . . , N ssfr −1, m=0, . . . , N sfr −1
In the speech signal decoding apparatus shown in FIG. 5 , adder 1050 adds a sound source vector after it is multiplied by gain to a pitch vector after it is multiplied by gain to produce an excitation vector. Excitation signal normalizing circuit 2510 , smoothing circuit 1320 and excitation signal restoring circuit 2610 smooth the norm calculated from the excitation vector in a noise period. As a result, short time average power in the excitation vector is smoothed in terms of time to improve degradation of decoded sound quality in the noise period.
FIG. 6 shows short time average power of an excitation vector after smoothing for the norm calculated from the excitation vector in a noise period. The horizontal axis represents a frame number, while the vertical axis represents power. The short time average power is calculated for every 80 msec. It can be seen from FIG. 6 that the smoothing according to the embodiment causes smoothed short time average power in the excitation vector (excitation signal) in terms of time.
FIG. 7 shows a speech signal decoding apparatus of a second embodiment of the present invention. The speech signal decoding apparatus shown in FIG. 7 differs from the speech signal decoding circuit shown in FIG. 5 in that first switching circuit 2110 and first to third filters 2150 , 2160 and 2170 are provided instead of smoothing circuit 1320 for performing processing in accordance with the characteristic of an input signal, smoothing coefficient calculating circuit 1310 is eliminated, and sound present/absent discriminating circuit 2020 is provided for discriminating between a sound present period and a sound absent period, noise classifying circuit 2030 is provided for classifying noise, power calculating circuit 3040 is provided for calculating power of a reproduced vector, and speech mode determining circuit 3050 is provided for determining a speech mode S mode , later described. Each of first to third filters 2150 , 2160 and 2170 functions as a smoothing circuit, but the contents of their smoothing processing performed are different from one another.
The speech signal decoding apparatus shown in FIG. 7 also forms a pair with the conventional art speech signal coding apparatus shown in FIG. 2 to constitute a speech signal coding and decoding system, and is configured to receive coded data outputted from the speech signal coding apparatus shown in FIG. 2 to perform decoding of the coded data. In FIG. 7 , the functional blocks identical to those in FIG. 5 are designated the same reference numerals as those in FIG. 5 .
Description is hereinafter made for power calculating circuit 3040 , speech mode determining circuit 3050 , sound present/absent discriminating circuit 2020 , noise classifying circuit 2030 , first switching circuit 2110 , first filter 2150 , second filter 2160 and third filter 2170 .
Power calculating circuit 3040 is supplied with a reproduced vector from synthesizing filter 1040 , calculates power from sum of squares of the reproduced vectors, outputs the calculation result to sound present/absent discriminating circuit 2020 . Assume herein that power is calculated for each subframe, and power in m-th subframe is calculated using a reproduced vector outputted from synthesizing filter 1040 in (m-1)th subframe. Assuming that the reproduced vector is [S syn (i), i=0, . . . , L sfr ], power (E pow ) is calculated with the following equation:
E
pow
=
1
L
sfr
∑
i
=
0
L
sfr
-
1
S
syn
2
(
i
)
Instead of the above equation, for example, a norm for a reproduced vector represented by the following equation may be used:
E
pow
=
∑
i
=
0
L
sfr
-
1
S
syn
2
(
i
)
Speech mode determining circuit 3050 is supplied with a previous excitation vector [e mem (i), i=0, . . . , (L mem −1)] held in storage circuit 1240 and with an index from code input circuit 1010 . This index specifies a delay L pd . The L mem is a constant determined by the maximum value of the L pd . In m-th subframe, speech mode determining circuit 3050 calculates a pitch prediction gain [G emem (m), m=1, . . . , N sfr ] as follows, from the previous excitation vector e mem (i) and the delay L pd :
G emem ( m ) = 10 log 10 ( g emem ( m ) ) where g emem ( m ) = 1 1 - E c 2 ( m ) E a1 ( m ) E a2 ( m ) E a1 ( m ) = ∑ i = 0 L sfr - 1 e mem 2 ( i ) E a2 ( m ) = ∑ i = 0 L sfr - 1 e mem 2 ( i - L pd ) E c ( m ) = ∑ i = 0 L sfr - 1 e mem ( i ) e mem ( i - L pd )
Speech mode determining circuit 3050 performs the following threshold value processing on the pitch prediction gain G emem (m), or an in-frame average value {overscore (G)} emem (n) in n-th frame for the G emem (m), thereby setting a speech mode S mode :
if ({overscore (G)} emem (n)≧3.5) then S mode =2 else S mode =0
Speech mode determining circuit 3050 outputs the speech mode S mode to sound present/absent discriminating circuit 2020 .
Sound present/absent discriminating circuit 2020 receives, as its inputs, the LSP: q j (m) (n) outputted from LSP decoding circuit 1020 , the speech mode S mode outputted from speech mode determining circuit 3050 , and the power outputted from power calculating circuit 3040 . The procedure for deriving the amount of variations in spectrum parameter in sound present/absent discriminating circuit 2020 is given below. The LSP: q j (m) (n) is used herein as the spectrum parameter. In n-th frame, a long time average q j (n) of the LSP is calculated with the following equation:
{overscore (q)} j (n)=β 0 ·{overscore (q)} j (n−1)+(1−β 0 )·{circumflex over (q)} j (N sfr ) (n)
j=1, . . . , N p
where β 0 =0.9. A variation amount d q (n) of the LSP in n-th frame is defined with the following equation:
d q ( n ) = ∑ j = 1 N p ∑ m = 1 N sfr D q , j ( m ) ( n ) q _ j ( n )
where D q,j (m) (n) corresponds to the distance between {overscore (q)} j (n) and {circumflex over (q)} j (m) (n). For example, one of the following equations may be used:
D q , j ( m ) ( n ) = ( q _ j ( n ) - q ^ j ( m ) ( n ) ) 2
or
D q , j ( m ) ( n ) = q _ j ( n ) - q ^ j ( m ) ( n )
The latter is used in this case. Generally, a period with a large variation amount d q (n) corresponds to a sound present period, while a period with a small variation amount d q (n) corresponds to a sound absent period (noise period). However, there is a problem that a threshold value for discriminating between the sound present period and sound absent period is not easily set since the variation amount exerts large variations with time and the range of values of variation amounts in the sound present period overlaps with the range of values of variation amounts in the sound absent period. Thus, the long time average of the variation amount d q (n) is used for discrimination between the sound present period and sound absent period. A long time average {overscore (d)} q1 (n) is derived using a linear filter or a non-linear filter. The average value, median value, mode of the variation amount d q (n) or the like can be applied thereto, for example. In this case, the following equation is used:
{overscore (d)} q1 ( n )=β 1 ·{overscore (d)} q1 ( n− 1)+(1−β 1 )· d q ( n )
where β 1 =0.9.
With threshold processing for the average value, a discrimination flag S vs is determined as follows:
if ({overscore (d)} q1 (n)≧c th1 ) then S vs =1 else S vs =0
where C th1 is a constant (for example, 2.2), and S vs =1 corresponds to a sound present period, while S vs =0 corresponds to a sound absent period. Since a period with high constancy has a small S vs even in the sound present period, it may be erroneously considered as a sound absent period. Thus, when a frame has large power and pitch prediction gain is large in a period, the period should be considered as a sound present period. At this point, the S vs is modified by the following additional determination:
if (Ê rms ≧C rms and S mode ≧2) then S vs =1 else S vs =0
where C rms is a certain constant (for example, 10000). S mode ≧2 corresponds to the in-frame average value {overscore (G)} op (n) of the pitch prediction gain equal to or higher than 3.5 dB. Sound present/absent discriminating circuit 2020 outputs the discrimination flag S vs to noise classifying circuit 2030 and to first switching circuit 2110 , and outputs {overscore (d)} q1 (n) to noise classifying circuit 2030 .
Noise classifying circuit 2030 receives, as its input, {overscore (d)} q1 (n) and the discrimination flag S vs outputted from sound present/absent discriminating circuit 2020 . In a sound absent period (noise period), a linear filter or a non-linear filter is used to derive a value {overscore (d)} q2 (n) which reflects average behaviors of {overscore (d)} q1 (n). When the S vs =0, the following equation is calculated:
{overscore (d)} q2 ( n )=β 2 ·{overscore (d)} q2 ( n− 1)+(1−β 2 )·{overscore (d)} q1 ( n )
where β 2 =094.
With threshold processing for {overscore (d)} q2 (n), noise is classified, and a classification flag S vs is determined as follows:
if ({overscore (d)} q2 (n)≧c th2 ) then S nz =1 else S nz =0
where C th2 is a certain constant (for example, 1.7), and S nz =1 corresponds to noise having a frequency characteristic inconstantly changing with time, while S nz=0 corresponds to noise having a frequency characteristic constantly changing with time. Noise classifying circuit 2030 outputs the S nz to first switching circuit 2110 .
First switching circuit 2110 receives, as its inputs, the gain [g exc (j), j=0, . . . , (N ssfr ·N sfr −1)] outputted from excitation signal normalizing circuit 2510 , the discrimination flag S vs from sound present/absent discriminating circuit 2020 , and the classification flag S nz from noise classifying circuit 2030 . First switching circuit 2110 switches a switch in accordance with the value of the discrimination flag and the value of the classification flag, thereby outputting the gain g exc (j) to first filter 2150 if S vs =S nz =0, to second filter 2160 if S vs =0 and S nz =1, or to third filter 2170 if S vs =1.
First filter 2150 receives, as its input, the gain [g exc (i), j=0, . . . , (N ssfr ·N sfr −1)] from first switching circuit 2110 , smoothes it with a linear filter or a non-linear filter to produce a first smoothed gain g exc,1 (j), and outputs it to excitation signal restoring circuit 2610 . In this case, the filter represented by the following equation is used:
{overscore (g)} exc,1 (n)=γ 21 ·{overscore (g)} exc,1 (n−1)+(1−γ 21 )·g exc (n)
where {overscore (g)} exc,1 (−1) corresponds to {overscore (g)} exc,1 (N ssfr ·N sfr −1) in the previous frame. Also, γ 21 =0.94.
Second filter 2160 smoothes the gain outputted from first switching circuit 2110 using a linear filter or a non-linear filter to produce a second smoothed gain {overscore (g)} exc,2 (j) which is then outputted to excitation signal restoring circuit 2160 . In this case, the filter represented by the following equation is used:
{overscore (g)}exc, 2 (n)=γ 22 ·{overscore (g)} exc,2 (n−1)+(1−γ 22 )·g exc (n)
where {overscore (g)} exc,2 (—1) corresponds to {overscore (g)} exc,2 (N ssfr ·N sfr −1) in the previous frame. Also, γ 22 =0.9.
Third filter 2170 receives, as its input, the gain outputted from first switching circuit 2110 , smoothes it with a linear filter or a non-linear filter to produce a third smoothed gain {overscore (g)} exc,3 (n) and outputs it to excitation signal restoring circuit 2160 . In this case, {overscore (g)} exc,3 (n)=g exc (n).
As described above, in the speech signal decoding apparatus shown in FIG. 7 , first filter 2150 , second filter 2160 and third filter 2170 can perform different smoothing processing, and power calculating circuit 3040 , speech mode determining circuit 3050 , sound present/sound absent discriminating circuit 2020 and noise classifying circuit 2030 can identify the nature of an input signal. The switching of the filters in accordance with the identified nature of the input signal enables smoothing processing of the excitation signal to be performed in consideration of the characteristics of the input signal. As a result, optimal processing is selected according to background noise to allow further improvement in degradation of decoded sound quality in a noise period.
FIG. 8 shows a speech signal decoding apparatus of a third embodiment of the present invention. The speech signal decoding apparatus shown in FIG. 8 differs from the speech signal decoding apparatus shown in FIG. 5 in that input terminal 50 and second switching circuit 7110 are added and the connections are changed. The speech signal decoding apparatus shown in FIG. 8 also forms a pair with the conventional speech signal coding apparatus shown in FIG. 2 to constitute a speech signal coding and decoding system, and is configured to receive coded data outputted from the speech signal coding apparatus shown in FIG. 2 to perform decoding the coded data. In FIG. 8 , the functional blocks identical to those in FIG. 5 are designated the same reference numerals as those in FIG. 5 .
A switching control signal is supplied from input terminal 50 . Second switching circuit 7110 receives an excitation vector outputted from adder 1050 , and outputs the excitation vector to synthesizing filter 1040 or to excitation signal normalizing circuit 2510 in accordance with the switching control signal. Therefore, the speech signal decoding apparatus can select whether the amplitude of the excitation vector is changed or not in accordance with the switching control signal.
FIG. 9 shows a speech signal decoding apparatus of a fourth embodiment of the present invention. The speech signal decoding apparatus differs from the speech signal decoding apparatus shown in FIG. 7 in that input terminal 50 and second switching circuit 7110 are added and the connections are changed. The speech signal decoding apparatus shown in FIG. 9 also forms a pair with the conventional speech signal coding apparatus shown in FIG. 2 to constitute a speech signal coding and decoding system, and is configured to receive coded data outputted from the speech signal coding apparatus shown in FIG. 2 to perform decoding the coded data. In FIG. 9 , the functional blocks identical to those in FIG. 7 are designated the same reference numerals as those in FIG. 7 .
A switching control signal is supplied from input terminal 50 . Second switching circuit 7110 receives an excitation vector outputted from adder 1050 , and outputs the excitation vector to synthesizing filter 1040 or to excitation signal normalizing circuit 2510 in accordance with the switching control signal. Therefore, the speech signal decoding apparatus can select whether the amplitude of the excitation vector is changed or not in accordance with the switching control signal, and if the amplitude of the excitation vector is to be changed, smoothing processing can be switched in accordance with the characteristic of the input signal.
While preferred embodiments of the present invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims. | A method of decoding a speech signal based on a CELP (Code Excited Linear Prediction) with improvement in degradation of decoded sound quality in a noise period. The method includes the steps of: calculating a norm of an excitation vector for each fixed period in a noise period; smoothing the calculated norm using a norm obtained in a previous period; changing the amplitude of the excitation vector in the period using the calculated norm and the smoothed norm; and driving a synthesizing filter by the excitation vector with the changed amplitude. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Recently, in order to obtain higher output of an engine, a plurality of intake ports are provided for each of the cylinders in the engine. For use in such an engine, an injector has been proposed having a plurality of guide holes through which fuel is guided into the respective intake ports.
The present invention relates to a multi-hole injector having a plurality of guide holes, and more specifically to a multi-hole injector with improved atomization and distribution.
2. Description of the Prior Art
An example of an injector having a plurality of guide holes is disclosed in U.S. Pat. No. 4,982,716. FIG. 5 shows the construction of the prior art injector. In FIG. 5, the injector includes a valve 126 for opening and closing a valve hole 118, and when the valve 126 is pulled upwardly, the valve hole 118 is opened and fuel Fp is injected from the valve hole 118. An adapter 145 is attached to a front end of the valve hole 118, and has a receiving hole 124 for receiving the injected fuel, the receiving hole 124 being divided downstream in a plurality of guide holes 137 through which the fuel is guided. The guide holes 137 are formed so as to be directed to corresponding intake ports (not shown). Assist air passages 138 are provided through side walls of the guide holes 137 so as to blow assist air into the guide holes 137.
In the injector thus constructed, fuel Fp injected from the valve hole 118 is introduced into the receiving hole 124 and then divided to be fed into the guide holes 137, where the fuel is atomized by assist air blown therein through the assist air passages 138 and is blown out toward the respective intake ports (not shown).
Another example of such a multi-hole injector is disclosed in U.S. Pat. No. 5,062,573. The construction of the injector is shown in FIGS. 6 and 7. The injector includes an adapter 145 formed with a receiving hole 124 which is divided downstream in three guide holes 137. The adapter 145 includes an atomization plate 130 disposed between the receiving hole 124 and the guide holes 137. As shown in FIG. 7, the atomization plate 130 includes an impactor 132 against which fuel injected from the valve hole 118 impacts to be atomized and three openings 136 through which the atomized fuel is introduced into the guide holes 137.
In the injector as disclosed in either of the above mentioned U.S. Pat. Nos. 4,982,716 and 5,062,573, the fuel injected from the valve hole 118 is received in the receiving hole 124 and then divided to be introduced into the guide holes 137. If there is any deviation in the positional relationship between the valve hole 118 and the guide holes 137, a larger amount of fuel will flow into one of the guide holes 137, while a smaller amount of fuel will flow into another one. This causes difficulty in achieving good distribution of fuel.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a multi hole injector which can provide good distribution and atomization.
Another object of the present invention is to provide a multi-hole injector which can provide good distribution and atomization characteristics without very severe dimensional control and which can be manufactured at a low cost.
To achieve the above objects, in accordance with the present invention, a distributing adapter is provided between a valve hole and guide holes, the adapter being formed with distributing holes which are the same in number as the guide holes and which extend between the valve hole and the corresponding guide holes. Thus, the amounts of fuel divided to be fed in the respective guide holes depend on the areas of the respective distributing holes, and control of the areas of the distributing holes with required degree of accuracy assures good distribution.
The invention will be more fully understood from the following detailed description and appended claims when taken with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of an embodiment of the multi-hole injector according to the present invention;
FIG. 2 is an enlarged view of the essential part of FIG. 1;
FIG. 3 is a view illustrating the injector mounted in an intake manifold as seen laterally;
FIG. 4 is a view illustrating injector mounted in the intake manifold as seen from above;
FIG. 5 is a view of a prior art injector construction;
FIG. 6 is a view of another prior art injector construction; and
FIG. 7 is a plan view of the plate shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, a preferred embodiment of the present invention will be described with reference to the drawings. In the following embodiment, the present invention is adapted to a double-hole injector for use in a vehicular engine.
FIG. 3 is a vertical sectional view showing associated portions of a cylinder 50 of the engine and an intake manifold 56, and FIG. 4 is a cross sectional view thereof. As shown in FIGS. 3 and 4, the cylinder 50 has two intake ports 52 and an exhaust port 54. Both of the intake ports 52 communicate with an intake air passage of the intake manifold 56, and a throttle valve 58 well known in the art is disposed in the passage so as to control opening and closing thereof. A double-hole injector 10 for injecting fuel separately toward the intake ports 52 of the cylinder 50 is mounted in a wall of the intake manifold 56. In FIG. 3, each of the intake ports 52 is provided with an intake valve 53.
FIG. 1 is a sectional view of the injector 10, and FIG. 2 is an enlarged view of a part of the injector 10 shown in FIG. 1. The description will be first related to an injector body 10a which is a main component of the injector 10. As seen in FIG. 1, the injector 10 includes a casing 11 in which a solenoid coil 12, a hollow core 14 and an armature 24 are housed. When the solenoid coil 12 is energized, the core 14, the armature 24 and a part of the casing 11 establish a magnetic circuit, which generates magnetic force effective to cause the armature 24 to slide upwardly from the position in FIG. 1 against the urging force of a valve spring 28 along with a valve 26 which will be mentioned later.
A valve housing 16 is provided in the casing 11 downwardly of the armature 24 as seen in FIG. 1. The valve housing 16 has inside thereof a hollow space in coaxial alignment with the hollow portions of the core 14 and the armature 24. As seen in FIG. 2, the valve housing 16 includes a valve hole 18 opening at the lower end thereof and communicating with the hollow interior, and a valve seat 17 is formed inside of the valve hole 18.
A solid valve 26 is provided within the valve housing 16. The valve 26 is fixed to the armature 24 so as to be slidingly movable with the armature 24, as described above. The valve 26 is normally pressed at the front end (lower end in FIGS. 1 and 2) thereof against the valve seat 17 of the valve housing 16 under the urging force of the valve spring 28 to close the valve hole 18.
In FIG. 1, a strainer 22 is fitted in the upper end hollow portion of the core 14, and the hollow portions arranged in series from the upper end portion of the core 14 to the valve hole 18 form a fuel passage 20 in the injector 10.
In FIGS. 1 and 2, an air adapter 45 is fitted on the front end of the injector body 10a or the front end (lower end in FIG. 1) of the valve housing 16, with a disc-like distributing adapter 30 interposed therebetween. The distributing adapter 30 may be mounted otherwise by welding or press-fitting.
The distributing adapter 30 is formed with two distributing holes 36 communicating with the valve hole 18 in the valve housing 16 and separated by a splitter 32. The distributing holes 36 extend through the distributing adapter 30 to the lower end surface thereof. Each of the distributing holes 36 is drilled so as to have an opening area equal to each other. Alternative machining means including punching, electric discharge machining or laser beam machining may be employed in place of drilling. The distributing holes 36 have lower openings directed to the corresponding intake ports 52 of the cylinder 50 as shown in FIGS. 3 and 4.
The air adapter 45 is formed with two guide holes 37 communicating with the lower openings of the distributing holes 36 in the distributing adapter 30 and separated by a splitter 34. Each of the guide holes 37 has a diameter substantially equal to or larger than that of each of the distributing holes 36 in the distributing adapter 30 and is disposed in a direction parallel to the corresponding distributing hole 36. The guide holes 37 are opened at the lower end surface of the air adapter 45. The lower openings of the guide holes 37 are directed to the corresponding intake ports 52 of the cylinder 50 as shown in FIGS. 3 and 4.
As shown in FIGS. 1 and 2, the air adapter 45 is also formed with air feed passages 38 extending through the air adapter 45 from the outer periphery thereof to the corresponding guide holes 37 so as to feed assist air. The air feed passages 38 communicate with the corresponding guide holes 37 at positions downstream of separation thereof by the splitter 34.
The front end portion (lower end portion in the drawing) of the injector 10 including the distributing adapter 30, the air adapter 45 and a portion of the casing 11 is fitted in an injector mounting member 40 of the intake manifold 56 as shown in two dot chain lines in FIGS. 1 and 2. Air seals 42, 44 are disposed so as to assure airtight mounting of the injector mounting member 40 relative to the casing 11 and the air adapter 45, respectively. Thus, an airtight air gallery 46 is defined within the injector mounting member 40 and communicates with the air feed passages 38.
The intake manifold 56 is provided with an air passage 48 communicating with the air gallery 46 and extending outside. As shown in FIG. 3, the air passage 48 communicates through an air pipe 60 with a portion of the intake manifold 56 upstream of the throttle valve 58.
In the injector thus constructed, when the solenoid coil 12 is energized to generate magnetic force, the valve 26 is actuated upwardly (as seen in FIG. 2) to open the valve hole 18, as described above. Therefore, the fuel supplied to the fuel passage 20 is injected from the valve hole 18 and separated in two streams flowing through the two distributing holes 36 in the distributing adapter 30 and then through the corresponding guide holes 37 in the air adapter 45.
The distributing holes 36 are equal in opening area, so that fuel is equally divided. With this construction, the positional relationship between the distributing holes 36 and the valve hole 18 is not so critical, and dislocation of the distributing holes 36 in relation to the center of the valve hole 18 will not interfere with equally divided fuel flow into the distributing holes 36.
In operation the pressure difference between the guide holes 37 and the intake manifold 56 causes the atmospheric air to flow through the air passage 48 into the guide holes 37. Specifically, the fuel introduced into the distributing holes 36 in the distributing adapter 30 is divided into two or more fuel streams. These fuel streams then flow through the guide holes 37 of the air adapter 45, where assist air is fed into the fuel streams. This permits effective atomization of the fuel to be injected toward the intake ports 52 of the cylinder 50, as shown in FIGS. 3 and 4.
Thus, in the double-hole injector, fuel is uniformly divided by the distributing adapter 30 and atomized by assist air, allowing the fuel to be uniformly distributed and injected in each of the intake ports of the cylinder. This assures improved combustibility of the engine as well as increased output and better fuel consumption performance.
A preferred embodiment of the present invention has been described with reference to the drawing, but the present invention is not limited by this embodiment and may be exemplified in various other embodiments.
For example, the inclination of the distributing holes 36 of the distributing adapter 30 can be different from that of the guide holes 37 of the air adapter 45, so that fuel fed through the distributing holes 36 of the distributing adapter 30 may impact against inclined surfaces of the splitter 34 of the air adapter 45 to be atomized, and when assist air is fed into the guide holes 37, the fuel thus atomized will be more finely atomized.
The assist air introduced from the intake manifold into the air passage 38 may be replaced by compressed air given by a compressor or the like.
Furthermore, the intake ports 52 of each cylinder 50, the distributing holes 36 in the distributing adapter 30 and the guide holes 37 in the air adapter 45 may be three or more in number, respectively.
The distributing holes 36 of the distributing adapter 30 may have different opening areas. In some types of engines, it is desirable to inhale different amounts of fuel through the ports. According to the present invention, such a requirement can be readily satisfied by providing the opening areas of the distributing holes in a ratio as desired. The opening areas of the distributing holes can be adjusted only by changing the contour of the holes, assuring ready achievement of required degree of accuracy.
Thus, according to the present invention, fuel is uniformly divided by the adapter and then atomized by assist air, assuring uniform distribution and injection of the fuel in the intake ports of each cylinder. | A fuel injector of the type in which a valve hole is opened and closed by a valve so as to intermittently inject pressurized fuel from the valve hole includes a distributing adapter fixedly attached to a front end of the valve hole, and an air adapter fixedly attached to a front end of the distributing adapter. The air adapter is formed with a plurality of guide holes directed to a plurality of intake ports of the engine, respectively, and assist air passages each communicating laterally with a corresponding one of the guide holes. The distributing adapter is formed with distributing holes of the same number as the guide holes, each of the distributing holes extending between the valve hole and a corresponding one of the guide holes. | 5 |
FIELD OF THE INVENTION
The present disclosure is related to a method and apparatus for embedding nanosensors on a surface for the sensing and recording of data.
BACKGROUND
Today, electrical circuits can be manufactured at the nanometer level. Current manufacturing processes include the use of lithography to imprint microscopic circuits on semiconductor materials. Other processes use molecular materials such as nanotubes to fabricate tiny electric devices such as diodes or transistors. These molecular nanoelectronics are assembled using contacts and gaps on an atomic scale to form integrated electrical circuits and nanosensors. The small size of nanosensors results in reduced weight, low power requirements, and greater sensitivity. With the development of revolutionary fabrication techniques, nanosensors can now be mass-produced at a fraction of the cost using convenient and/or known methods.
Nanotechnology has far-reaching benefits spanning from physical and electro-sensors to chemical and biosensors. Industries affected by this technology range from security to transportation. In the security industry, discrete sensors are often desired in order to clandestinely monitor activities. The vast majority of sensors used today are large and easily visible, and have to be camouflaged to hide their position. Thus, it is often possible for criminals to avoid detection by locating the sensors and avoiding or disabling them. As a result, legal costs increase as more effort is needed to examine and produce sufficient evidence to sustain a conviction. In the transportation and insurance industries, a multitude of sensors recording data is the optimal technique for precise re-enactment of a traffic accident. Such data collection is not possible with currently-available sensors, because the placement of such sensors directly on the road would impede traffic flow. When the use of sensors is necessary, such as for the weight inspection of commercial cargo trucks, vehicles are forced to exit the freeway. Further, if placed in the freeway, the sensors would be subject to heavy wear and tear from the high volume of traffic.
The use of multiple discrete sensors could be used in a variety of other situations such as, by way of example, re-enactment of crime scenes, monitoring and control of pedestrian and automobile traffic, providing building safety and security, collecting data for demographic purposes, even providing aid in the creation of video games. This is only a small illustration of the benefits available from a device that detects data invisibly from virtually any position.
What is needed is a device that implements nanosensor technology to allow data to be detected inconspicuously and simultaneously from a multitude of unanticipated locations.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a block circuit diagram of a sensor.
FIG. 2 depicts a wall having sensors embedded therein.
FIG. 3 depicts an alternate embodiment of the embodiment shown in FIG. 2 .
FIG. 4 depicts a wall covering having sensors embedded therein.
FIG. 5 depicts an alternate embodiment of the embodiment shown in FIG. 4 .
FIG. 6 depicts an orientation device.
FIG. 7 depicts an alternate embodiment of the embodiment shown in FIG. 6 .
FIG. 8 depicts an article of wearing apparel having sensors embedded therein.
FIG. 9 depicts a window having sensors embedded therein.
FIG. 10 depicts a window covering having sensors embedded therein.
DETAILED DESCRIPTION
FIG. 1 depicts a schematic circuit diagram of a sensor. In the embodiment shown in FIG. 1 , the sensor is comprised of an input 104 , an analog to digital converter 106 , memory 108 , an output 110 , a power source 112 , and an orientation mechanism 114 . As is shown in FIG. 1 , the input 104 of the sensor can detect data 102 . The input 104 is connected with a converter 106 . The converter 106 can convert the detected data 102 from an analog signal into a digital signal. The converter 106 is connected with memory 108 . The memory 108 can store the digital signal outputted by the converter 106 . The memory 108 is connected with an output 110 . The output 110 can transmit the data to a source for data collection and reconstruction. Also shown is a power source 112 connected with all components of the sensor. Also, as shown in the embodiment shown in FIG. 1 , an orientation mechanism 114 can be attached to the input 104 . In the event that the input 104 of the sensor was incorrectly situated, the orientation mechanism 114 can be utilized to orient the sensor to allow for the detection of data 102 .
In alternate embodiments, the sensor can be constructed in any convenient and/or known manner using any convenient and/or known material or components. The sensor, by way of example, can be fabricated using electron beam lithography, atomic force microscopes, electrochemical deposition and etching, electromigration, voltage etching, and/or any other micro-electronic and/or nano-manufacturing process and/or algorithm. The material of the sensors, by way of example, can be silicon and/or any other semi-conducting crystalline material, nanotubes and/or any other semi-conducting molecules, particles, and/or atoms, and/or any other known and/or convenient material.
In further alternate embodiments, the component arrangement of the sensor can be in any convenient and/or known configuration. By way of example, the input 104 can be directly connected with a data collection source thereby removing the converter 106 , memory 108 , and output 110 ; the converter 106 can be directly connected with a data collection source thereby removing the memory 108 and output 110 ; the converter 106 can be connected directly to the output 110 thereby removing the memory 108 ; the memory 108 can be connected with a data collection source thereby removing the output 110 ; the orientation mechanism 114 can be removed or positioned in any known and/or convenient location on the sensor. In addition, the power source 112 can be constructed in any convenient and/or known manner using any convenient and/or known material. By way of example, the power source can use direct or alternating current being rechargeable or non-rechargeable. Also, by way of example, the components of the sensor can be connected in any convenient and/or known parallel/series combination. Furthermore, additional components can be included and/or excluded in any convenient and/or known arrangement.
In addition, in alternate embodiments, the input 104 of the sensor can be calibrated to detect a variety of data 102 . By way of example, the input 104 of the sensor can be calibrated to detect image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. Also, in alternate embodiments, the output of the sensor can be, by way of example, a transmitter, transponder, antenna, receiver, responder or any other convenient and/or known device capable of data transmission and/or storage. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 102 .
In still further alternate embodiments, the device can include a clock and/or timing mechanism 116 . The clock and/or timing mechanism can be used to time stamp data at is it received. In alternate embodiments, the clock and/or timing mechanism 116 can be used to cause the device to record data at specified time intervals and/or can be used to erase memory at specified times and/or time intervals. In alternate embodiments, the clock and/or timing mechanism 116 may not be present, can be external to the device and timing can be controlled by a transmitted or received signal and/or signals and/or controlled by any other convenient mechanism.
FIG. 2 depicts a side view of a wall having embedded sensors therein. As shown in the embodiment shown in FIG. 2 , sensors 202 are embedded in a wall 204 composed of gypsum. The placement of the sensors 202 in the gypsum 204 allows for the inconspicuous detection of data 101 from the various locations of the sensors 202 . In the embodiment shown in FIG. 2 , the sensors 202 can be positioned and fixed during construction of the gypsum 204 thus eliminating the orientation of the sensors 202 . The sensors 202 shown in FIG. 2 are similar to the sensor 202 depicted in the embodiment shown in FIG. 1 . Thus, as shown in the embodiment shown in FIG. 2 , the sensors 202 detect data 101 , covert the data from an analog to digital signal, and then transmit the data to a data collection source.
In alternate embodiments, the sensors 202 can be embedded in the wall 204 using any convenient and/or known method. By way of example, the sensors 202 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the wall 204 during or after construction. In addition, the wall 204 can be composed of any convenient and/or known material and can be constructed using any convenient and/or known method of construction. By way of example, the wall can be composed of drywall, sheetrock, wallboard, greenboard, backerboard, plaster, brick or lumber. Also, in alternate embodiments, the sensors can be calibrated to detect a variety of data 101 , including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The wall 204 , in alternate embodiments, can be interior and/or exterior and used to detect inside and/or outside data 101 in and/or from any convenient and/or known structure. In alternate embodiments, the sensors 202 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 202 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 101 .
FIG. 3 depicts an alternate embodiment of the embodiment shown in FIG. 2 . In the embodiment shown in FIG. 3 , sensors 302 are embedded in a wall 304 composed of stucco. In the embodiment shown in FIG. 3 , the sensors 302 are positioned and fixed during construction of the stucco 304 thus eliminating the orientation mechanism. The embodiment shown in FIG. 3 is intended to illustrate an alternate composition of a wall 304 in which the sensors 302 can be embedded to detect data 101 invisibly from one or more sensor locations.
In alternate embodiments, the sensors 302 can be embedded in the wall 304 using any convenient and/or known method. By way of example, the sensors 302 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the wall 304 during or after construction. In addition, the wall 304 can be composed of any convenient and/or known material and can be constructed using convenient and/or known methods of construction. Also, in alternate embodiments, the sensors can be calibrated to detect a variety of data 101 , including, byway of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The wall 304 , in alternate embodiments, can be interior and/or exterior and used to detect inside and/or outside data 101 in and/or from any convenient and/or known structure. In alternate embodiments, the sensors 302 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 302 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 101 .
FIG. 4 depicts a side view of a wall covering having embedded sensors therein. In the embodiment shown in FIG. 4 , sensors 402 are embedded in a wall covering 404 composed of wallpaper that is attached to a wall 406 . The sensors 402 in the embodiment shown in FIG. 4 detect data 101 invisibly by being embedded in the wallpaper 404 . In the embodiment shown in FIG. 4 , the sensors 402 are positioned and fixed during construction of the wallpaper 404 thus eliminating the orientation mechanism. The sensors 402 as shown in the embodiment shown in FIG. 4 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the sensors 402 can be embedded in the wall covering 404 using any convenient and/or known method. By way of example, the sensors 402 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the wall covering 404 during or after construction. In addition, the wall covering 404 can be composed of any convenient and/or known material and can be constructed using any convenient and/or known method of construction. In alternate embodiments, the wall covering 404 can be associated with the wall 406 or any other surface using any convenient and/or known method. Also, in alternate embodiments, the sensors can be calibrated to detect a variety of data 101 , including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The wall covering 404 , in alternate embodiments, can be interior and/or exterior and used to detect inside and/or outside data 101 in and/or from any convenient and/or known structure. In alternate embodiments, the sensors 402 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 402 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 101 .
FIG. 5 depicts a side view of a spreadable medium having sensors embedded therein associated with a surface. In the embodiment shown in FIG. 5 , the spreadable medium 504 composed of paint is applied to a wall 506 . Sensors 502 are embedded in the paint 504 to detect data 101 . In the embodiment shown in FIG. 5 , the sensors have been oriented after application of the paint 504 to the wall 506 and can be in a fixed position. Because the sensors 502 are embedded within the paint 504 , the sensors 502 are able to detect data 101 discreetly. The sensors 502 as shown in the embodiment shown in FIG. 5 are similar to the sensors 202 shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the spreadable medium 504 can be composed of any convenient and/or known material. By way of example, the spreadable medium 504 can be paint, cement, asphalt, concrete, acrylic, chroma, coloring, dye, emulsion, enamel, flat, gloss, greasepaint, latex, oil, overlay, pigment, rouge, stain, tempera, varnish, veneer or wax. Also, in alternate embodiments, the spreadable medium can be associated using any convenient and/or known method to any convenient and/or known surface. In addition, in alternate embodiments, the sensors can be calibrated to detect a variety of data 101 , including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The spreadable medium 504 , in alternate embodiments, can be used to detect inside and/or outside data 101 in and/or from any convenient and/or known surface being interior and/or exterior. In alternate embodiments, the sensors 502 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 502 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 101 .
FIG. 6 depicts an orientation device that can be used to orient the sensors. As shown in the embodiment shown in FIG. 6 , a magnetic orientation device 602 is being passed over a surface covered by a spreadable medium 606 composed of paint with sensors 604 embedded therein. The paint 606 is not settled and the sensors 604 , at first, are not correctly situated. As can be seen in the embodiment shown in FIG. 6 , the magnetic orientation device 602 is being passed over the unsettle paint 606 . The sensors 604 are pulled to the surface of the paint 606 by the magnetic force resultant from the orientation mechanism on the sensors 604 and the magnetic orientation device. After the sensors 604 have been oriented properly, the paint 606 dries and the sensors 604 are in a fixed position on the wall 608 . The sensors 604 as shown in the embodiment shown in FIG. 6 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the orientation device 602 can be any constructed in any convenient and/or known manner using any convenient and/or known method and/or force to orient the sensors 604 . Also, in alternate embodiments, the spreadable medium 606 can be composed of any convenient and/or known material. In alternate embodiments, the spreadable medium 606 can be associated using any convenient and/or known method to any convenient and/or known surface. In addition, in alternate embodiments, the sensors 604 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. The orientation mechanism on the sensors 604 can be any convenient and/or known material being drawn and/or attracted to any convenient and/or known force. In an alternate embodiment, the device 602 can be used to collect and/or retrieve data and/or recharge the sensors with or without the capability to orient the sensors. In further alternate embodiments, any known and/or convenient manner to orient the sensors can be used or the sensors may not be oriented.
FIG. 7 depicts an alternate embodiment of the embodiment shown in FIG. 6 . As shown in the embodiment shown in FIG. 7 , an orientation device 702 is embedded in a wall 608 . The wall 608 is covered with a spreadable medium 606 composed of paint with embedded sensors 604 . The paint 606 is not settled and the sensors 604 , at first, are not correctly situated. As can be seen in the embodiment shown in FIG. 7 , the orientation device 702 is activated. The sensors 604 are repelled from the orientation device 702 and pushed toward the outer surface of the paint 606 . After the sensors 604 have been oriented properly, the paint 606 dries and the sensors 604 are in a fixed position on the wall 608 . The sensors 604 as shown in the embodiment shown in FIG. 6 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 with the exception of the orientation mechanism being attached at the opposite end.
In further alternate embodiments, the orientation device 702 can be any constructed in any convenient and/or known manner using any convenient and/or known method and/or force to orient the sensors 604 . Also, in alternate embodiments, the wall 606 can be composed of any convenient and/or known material and the orientation device 702 can be embedded in any convenient and/or known arrangement using any convenient and/or known manner and/or method of construction. In alternate embodiments, the spreadable medium 606 can be associated using any convenient and/or known method to any convenient and/or known surface. In addition, in alternate embodiments, the sensors 604 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. The orientation mechanism on the sensors 604 can be arranged in any convenient and/known manner and can be constructed with any convenient and/or known material being repelled from and/or attracted to any convenient and/or known force. In an alternate embodiment, the device 606 can be used to collect and/or retrieve data and/or recharge the sensors with or without the capability to orient the sensors.
FIG. 8 depicts an article of wearing apparel having sensors embedded therein. As shown in the embodiment shown in FIG. 8 , sensors 802 are embedded in a long-sleeve shirt 804 . The sensors 802 as shown in the embodiment shown in FIG. 8 detect and transmit biological data. In the embodiment shown in FIG. 8 , the sensors 802 are positioned and fixed during construction of the shirt 804 thus eliminating an orientation mechanism. The sensors 802 as shown in the embodiment shown in FIG. 8 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the sensors 802 can be embedded in an article of wearing apparel 804 using any convenient and/or known method. By way of example, the sensors 802 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the article of wearing apparel during or after construction. In addition, the article of wearing apparel 804 can be composed of any convenient and/or known material and can be constructed using any convenient and/or known method of construction. Also, in alternate embodiments, the sensors can be calibrated to detect a variety of data, including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. For example, the sensors 802 can be calibrated to detect motion data. Because of the multiple sensor locations within the article of wearing apparel 804 , the motion data can provide for a detailed reconstruction of any movement. In alternate embodiments, the sensors 802 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 802 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data.
In still further alternate embodiments, the sensors 106 can be included in a spreadable liquid and/or other known and/or convenient medium which can be associated with an article of wearing apparel 804 in any known and/or convenient manner.
FIG. 9 depicts a front view of a window having sensors embedded therein. In the embodiment shown in FIG. 9 , the sensors 902 are embedded in a window 904 . Because of the small size of the sensors 902 , the sensors 902 are invisible and do not impair images seen through the window 904 . In the embodiment shown in FIG. 9 , the sensors 902 are positioned and fixed during construction of the window 904 thus eliminating an orientation mechanism. The sensors 904 as shown in the embodiment shown in FIG. 9 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the sensors 904 can be embedded in the window 904 using any convenient and/or known method. By way of example, the sensors 904 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the windows during or after construction. In addition, the window 904 can be composed of any convenient and/or known material and can be constructed using any convenient and/or known method of construction. In alternate embodiments, the sensors 904 can be placed in the window frame as well in the glass or in any convenient and/or known combination and/or arrangement thereof. Also, in alternate embodiments, the sensors 904 can be calibrated to detect a variety of data, including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The window 904 , in alternate embodiments, can be used to detect inside and/or outside data in and/or from any convenient and/or known structure. In alternate embodiments, the sensors 802 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 802 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data.
FIG. 10 depicts a side view of a window covering having sensors embedded therein attached to a window. As shown in the embodiment shown in FIG. 10 , sensors 1002 are embedded in a window covering 1006 comprised of drapes. The drapes 1006 are used to cover the window 1004 . The sensors 1002 detect data 101 unnoticeably because the sensors 1002 are embedded within the material of the drapes 1006 . In the embodiment shown in FIG. 10 , the sensors 1002 are positioned and fixed during construction of the drapes 1006 thus eliminating an orientation mechanism. The sensors 1002 as shown in the embodiment shown in FIG. 10 are similar to the sensors 202 as shown in the embodiment shown in FIG. 2 .
In alternate embodiments, the sensors 1002 can be embedded in the window covering 1006 using any convenient and/or known method. By way of example, the sensors 1002 can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted in the window covering during or after construction. In addition, the window covering 1006 can be composed of any convenient and/or known material and can be constructed using any convenient and/or known method of construction. For example, the window coverings 1006 can be composed of mini-blinds or any other blinds and/or material used to cover a window 1004 . In alternate embodiments, the sensors 1002 can be placed in the window 1004 , the window frame, or the window covering 1006 in any convenient and/or known combination and/or arrangement thereof. In addition, in an alternate embodiment, the window covering can be associated with the window in any convenient and/or known manner and/or method. Also, in alternate embodiments, the sensors 1002 can be calibrated to detect a variety of data 101 , including, by way of example, image, temperature, sound, motion, chemical, biological, or any other convenient and/or known data capable of detection. The windows covering 1006 , in alternate embodiments, can be used to detect inside and/or outside data 101 in and/or from any convenient and/or known structure. In alternate embodiments, the sensors 1002 can be constructed in any convenient and/or known manner with any convenient and/or known material using any convenient and/or known combination of components and/or circuitry. Further, in alternate embodiments, the sensors 1002 can output the data using any convenient and/or known method and/or can store the data for collection at a later time. Using a plurality of sensors, recorded events can be reconstructed from the transmitted and/or stored data 101 .
In one embodiment of the invention, sensors that are fabricated on the nanometer level (typically 100 μm–30 nm) are embedded in a wall during the construction of the wall. The nanosensors are able to detect external data, convert the data from an analog signal to a digital signal, store the data in memory, and transmit the data to a receiver. The external data may include temperature, light, movement, chemical makeup, and pressure applied. The receiver collects and compiles this data from the sensors and outputs an intelligible readout and/or report of the data collected. The data can be stored and retrieved at a later time to reconstruct prior events.
The wall can be constructed in any manner using any conventional material. Commercially available examples include gypsum, drywall, sheetrock, wallboard, greenboard, backerboard, stucco, or plaster. The wall can be interior or exterior. In addition, the wall may be constructed on-site or imported from an off-site location. The sensors can then be embedded within the wall using any method. By way of example, the sensors can be buried, deposited, enclosed, fastened, fixed, infixed, ingrained, inlayed, inserted, installed, lodged, planted, plunged, pressed, stuck, or implanted into an outer surface of the wall. The wall structure can then be used to detect and record data from any source that the wall surface is exposed to, inside or outside. The sensors can be embedded during or after construction of the wall in any conventional arrangement.
In an alternate embodiment of the device, nanosensors are embedded in a wall covering which is then associated with a wall. The wall covering can be constructed in any manner. The wall covering can also constructed using any conventional material, including by way of example, as paper, tile, or paneling material. The material can be artistic or functional. The sensors can be embedded within the wall covering using any method. By way of example, the sensors can be buried, deposited, enclosed, fastened, fixed, infixed, planted, ingrained, inlayed, lodged, inserted, installed, plunged, pressed, stuck, or implanted in the wall covering. The wall covering can then be associated with the wall in any manner. By way of example, the wall covering can be affixed, attached, bound, bonded, brazed, clasped, fastened, fixed, fused, glued, hung, lodged, pasted, soldered, stuck, united, or welded to the wall. The wall covering can be associated using a removable or non-removable adhesive. The wall covering can be used to detect data inside or outside of a structure. The sensors can be embedded during or after construction of the wall covering and can be placed in any conventional arrangement.
In a further embodiment of the invention, nanosensors are dispersed in a spreadable medium and the medium applied onto a surface. The spreadable medium can be composed of any conventional material. By way of example, the spreadable medium can be composed of paint, cement, asphalt, concrete, acrylic, chroma, coloring, dye, emulsion, enamel, flat, gloss, greasepaint, latex, oil, overlay, pigment, rouge, stain, tempera, varnish, veneer, wax, or any other material that can be applied to a surface. The spreadable medium can be applied to a surface using any known method. By way of example, the spreadable medium can be applied to the surface by being painted, brushed, smeared, coated, washed, buffed, glazed, glossed, laid, set, spread or any other method of association. The spreadable medium can be used to detect inside or outside data from any surface.
In a further embodiment of this device, nanosensors are embedded in an article of apparel. The article of apparel can be composed of any conventional material and the sensors can be embedded using any method. By way of example, the sensors can be buried, deposited, enclosed, fastened, fixed, infixed, planted, ingrained, inlayed, lodged, inserted, installed, plunged, pressed, stuck, or implanted in the article of wearing apparel. The sensors can be embedded during or after construction of the article of wearing and placed in any arrangement.
In an alternate embodiment of this device, nanosensors are embedded in a window. The window can be composed of any material and the sensors can be embedded using any method. By way of example, the window can be made of aluminum, vinyl, wood, fiberglass, fibrex and can be a single hung, double hung, casement, awning, bay, bow, fixed frame, skylight, or slider. By way of example, the sensors can be buried, deposited, enclosed, fastened, fixed, infixed, planted, ingrained, inlayed, lodged, inserted, installed, plunged, pressed, stuck, or implanted in the window. The window can be used to detect data inside or outside of any structure. The sensors can be embedded during or after construction of the window and placed in any conventional arrangement.
Further, in an alternate embodiment, nanosensors are embedded in window coverings. The window coverings can be composed of any material and the sensors can be embedded using any conventional method. The window covering, by way of example, can be composed of blinds, drapes, shades, or any other material used to cover a window. The sensors can be embedded using any method, including by way of example, being buried, deposited, enclosed, fastened, fixed, infixed, planted, ingrained, inlayed, lodged, inserted, installed, plunged, pressed, stuck, or implanted in the window covering. The window covering can be used to detect data inside or outside of a structure. The sensors can be embedded during or after construction of the window covering and placed in any conventional arrangement.
In alternate embodiments, nanosensors are embedded in a number of other unanticipated locations. These locations include, by way of example, flooring, roofs, and telephone poles.
The sensors can be constructed in any manner using any conventional material. The sensors, by way of example, can be fabricated using electron beam lithography, atomic force microscopes, electrochemical deposition and etching, electromigration, voltage etching, and/or any other micro-electronic and/or nano-manufacturing process and/or algorithm. The material of the sensors, by way of example, can be composed of silicon and/or any other semi-conducting crystalline material, nanotubes and/or any other semi-conducting molecules, particles, and/or atoms, and/or any other semi-conducting material.
There are various changes and modifications that can be made as would be apparent to those skilled in the art. It is intended that the device be limited only by the scope of the claims appended hereto. | The device implements nanotechnology by embedding nanocircuits with sensors to surfaces such as walls, wall coverings, clothing, windows, window coverings, flooring, roofs, roadways and telephone poles. Using a plurality of nanocircuits in a multitude of locations, events can be continuously detected and recorded without intrusion, and reconstructed at a later time. | 8 |
BACKGROUND OF THE INVENTION
Synthetic resinous materials are prepared in a variety of manners such as mass polymerization suspension polymerization, solution polymerization and emulsion polymerization. For many resinous materials it is desirable that they be prepared by an emulsion polymerization technique in order that the desired particle size molecular weight or grafting reaction is more readily obtained by the emulsion polymerization route than by solution, suspension or mass polymerization. Latex solids have been recovered most frequently by adding an electrolyte to the latex, usually with heating and agitation to cause the latex particles to agglomerate into macro particles which are readily filtered, washed and dried. Typical processes are discussed in U.S. Pat. Nos. 3,248,455; 3,345,430; and 3,438,923, the teachings of which are herewith incorporated by reference thereto. For some purposes the use of electrolyte in coagulation results in undesired retention of the emulsifier employed in the emulsion polymerization and oftentimes retention of at least some of the electrolyte employed for the coagulation. In order to overcome the problem of electrolyte retention, nitrile polymer latexes have been coagulated by shear coagulation. Shear coagulation is a process wherein a latex is subjected to mechanical shear until at least a major portion of the latex particles have agglomerated and in the event that the system which is subjected to shear has a solids content of about 20 to 30 weight percent, the shear coagulated product is a more or less grainy paste. U.S. Pat. No. 3,821,348 discloses a shear coagulation process wherein the resultant paste of a nitrile polymer latex is extruded and placed in hot water for a period of time and the resultant extrude washed and dried.
It would be desirable if there were available an improved process for the recovery of latex solids.
It would also be desirable if there were available an improved process for the recovery of latex solids which required minimal energy.
It would also be desirable if there were available an improved process for the recovery of latex solids which required minimal quantities of water and steam.
SUMMARY OF THE INVENTION
These benefits and other advantages in accordance with the present invention are achieved in a process for the recovery of synthetic resinous thermoplastic latex solids from a latex, the steps of the method comprising providing a latex of a synthetic resinous thermoplastic polymer, the latex containing from about 10 to about 50 weight percent solids, subjecting the latex to mechanical shear sufficient to transform the latex into a paste-like mass, admixing the paste-like mass with steam under pressure with mechanical shear provided by the admixture of steam with said mass to thereby heat the paste-like mass above the softening point of the polymer and form a plurality of macro particles of which at least 90 weight percent are retained on an 80 mesh U.S. Sieve Size screen and subsequently subjecting said macro particles to mechanical working to expel at least a majority of water associated therewith.
The process of the present invention is operable with any synthetic resinous thermoplastic latex having solids content by weight of from about 10 to about 50 weight percent. Typically, latexes which are useful in the present process include polystyrene latex, polymethyl methacrylate, polybutadiene polyisoprene latexes, polyvinylacetate latexes, polyvinylchloride latexes, various copolymer latexes including styrene and butadiene latexes, vinylchloride vinylacetate copolymers, vinylidene chloride, vinylchloride latexes, polymethylmethacrylate latexes, polymethylacrylate latexes, and the like.
Latexes which particularly benefit from treatment in accordance with the present invention are styrene-acrylonitrile-rubber latexes wherein styrene-acrylonitrile copolymer is grafted to a diene rubber substrate such as polybutadiene. The only component in addition to the latex that is required is process steam. Steam of commercial purity under pressures of from about 25 to about 400 pounds per square inch guage are generally satisfactory.
During the heating of the paste-like mass prepared by shear coagulation, the temperature of the solids should be raised at least to the softening point of the polymer to permit desired agglomeration. Therefore, the steam pressure for a particular latex must be sufficiently high to raise the polymer to its softening point. In the event it is desired to dilute the latex prior to shear coagulation in order to provide a paste of a more flowable consistency, water is employed. Usually it is desirable that such water be deionized in order to minimize possible introduction of materials which might affect the thermal stability of the desired end product.
Further features and advantages of the present invention will become more apparent from the following specification taken in connection with the drawing wherein:
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is a simplified schematic representation of the process in accordance with the present invention.
FIG. 2 is a representation of a steam paste mixing device such as is employed in FIG. 1.
FIG. 3 is a schematic sectional representation of the steam paste mixing inlet portion of the device of FIG. 2.
DETAILED DESCRIPTION OF DRAWING
In FIG. 1 there is schematically depicted an apparatus 10 suitable for the practice of the process of the present invention. The apparatus 10 comprises in cooperative combination a shear coagulator 11. The shear coagulator 11 has in association therewith a latex carrying conduit 12 which discharges a synthetic resinous thermoplastic latex into coagulator 11. The conduit 12 has associated therewith a steam supply conduit 13 attached to supply steam to latex in the conduit 12 and raise the temperature to a desirable coagulating temperature; for example, 40°-90° C. The shear coagulator 12 discharges a steam of paste-like mass 14 to a mixing and forwarding apparatus 16. The mixing and forwarding apparatus 16 beneficially can be a rotary type mixer with blades affixed to a shaft, the blades being inclined at an angle to the shaft to provide a forwarding action. The mixer 16 has an inlet 17 and a discharge 18. The discharge 18 of the mixer 16 is in communication with a pump 19. The pump 19 beneficially is a screw type pump such as is commercially available under the trade name of Moyno. The pump 19 has an inlet in operative communication with the discharge 18, mixing and forwarding device 16, and a discharge conduit 21 in operative communication with a steam mixing and shearing device 22. The mixing and shearing device 22 has a steam inlet 23 and an outlet 24. The mixing and shearing device 22 forms the paste-like mass from the pump 19 into a wet granular mass. The wet granular mass passes through the discharge 24 into a mechanical dewatering apparatus 26 having an inlet communicating with the discharge 24. The mechanical dewatering apparatus 26 has a first or solids discharge 27 and a liquid discharge line 28. The liquid discharge line 28 is in communication with a filter or screen assembly 29. The filter assembly 29 has a liquid discharge 31 and a solids discharge 32. The solids discharge 32 discharges to the inlet 17 of the mixing and forwarding device 16. The solids discharge 27 passes to a grinder 33 which commutes the solid material from the mechanical dewatering device 26. The particulated solids from the grinder 33 are passed through conduit 35 to a cooler such as a rotary cooler 35 having a cooling water inlet 37 and a cooling water discharge 38. Particulate material from the cooler 36 is discharged via line 39 into a storage hopper 40 and subsequently passed from the hopper 40 through line 41 for packaged shipment and final use.
In FIG. 2 there is a schematic representation of a steam-paste mixing apparatus generally designated by the reference numeral 50. The apparatus 50 is generally equivalent to the mixer designated by the reference numeral 32 in FIG. 1. The mixer 50 comprises an inlet mixing assembly generally designated by the reference numeral 51 which comprises steam valve 52 having a steam inlet 53 and a discharge region 54. The discharge region 54 of the valve 52 is in communication with a paste inlet mixing and shearing assembly 55 having a paste inlet 56 and a high shear region 57. The high shear region 57 has a discharge end 58 which is in full communication with a pipe section 59. The pipe section 59 remote from the high shear region 57 is connected to a reducer 61. The discharge of the reducer 61 is in communication with a backpressure valve 62. Beneficially the valve 62 is a fluid operated pinch valve. By fluid operated pinch valve is meant a valve that comprises a housing, a flexible tube is disposed within the housing and serves to convey fluids therethrough. Space between the tube and the housing is in communication with a source of a pressurized fluid which can be selectively applied thereto to collapse the flexible tube and thereby close the valve or to remove at least a portion of the pressurized fluid to thereby open the valve. The valve 62 remote from the reducer 61 is in communication with conduit 63. The conduit 63 remote from the valve 62 terminates in a disentrainment chamber 64. The chamber 64 has an overhead vent 65 through which steam may escape and a bottom discharge 66 through which the solid wet particulate product is withdrawn.
FIG. 3 is a schematic sectional representation of the steam paste mixing section 51 of FIG. 2. Disposed within the high shear region 57 is a tube 68. The tube 68 has a first inlet end 69 and a second or discharge end 71. The tube 68 is adjustably mounted within the mixing section in such a manner that the location of the inlet end 69 can be axially positioned toward or away from the valve 52 and thereby vary the shearing and agitating effect of the steam on the latex paste-like mass provided from inlet 56.
DETAILED DESCRIPTION OF INVENTION
In the practice of the process in accordance with the present invention with particular reference to the Drawing, latex is passed through conduit 12 where it is heated by steam introduced from conduit 13. The shear coagulator 11 is adjusted until a desired paste-like configuration is obtained. For example, a suitable shear coagulator is a butter churn of the generally horizontal cylindrical drum variety having internal blades which rotate about the axis of the drum, the blades having a clearance from the drum of about one-eighth of an inch. When temperature of the incoming latex and rotational speed of the shear coagulator 11 have been adjusted to provide desired paste-like effluent, the paste-like mixture is passed into inlet 17 of the mixer 16. The mixer 16 provides the dual function of forwarding the paste toward the pump 19 as well as mix into the paste any solids which are returned through line 32. In the event that the paste consistency is thicker than desired, the mixer 16 can be employed to optionally dilute the paste with water to provide a more flowable stream. The pump 19 beneficially forwards the paste through the line 21 into the steam mixing and shearing device 22. Such a mixing and shearing device is schematically depicted in FIGS. 2 and 3. When paste starts to flow, for example, through inlet 56, steam is introduced through the opening 53 and controlled by the valve 52. Pressure within the pipe section 59 is controlled in part by the appropriate opening and closing of the valve 62 and adjustment of the tube 69 until the desired crumb is obtained. The resultant slurry preferably at a temperature below the softening temperature of the latex polymer passes from the mixer 50 through opening 66 into mechanical dewatering device such as device 26. A suitable dewatering device is a so-called expeller or expressing apparatus which basically is a screw extruder having longitudinal slots formed in the barrel thereof of width sufficient to permit water or like liquids to flow therethrough and yet sufficiently narrow to prevent solids from passing through. Roller mills and like expressing apparatus are also suitable and may be used alone or in combination. The solids material discharged from the expeller is ground to a desirable size, collected if necessary by a collector such as collector 36 and stored for future use. For many applications it is not necessary to remove all of the water. Typically the water content of the material emerging from the mechanical dewatering device such as device 26 is about 10 to 20 weight percent. As each latex batch appears to have a personality of its own, it is generally desirable to prepare as large a charge of latex as is conveniently possible in order to avoid individual adjustment of the apparatus for the coagulation of individual batches. Conveniently, a steam mixer such as is depicted in FIG. 2 for a throughput slightly in excess of 2,000 pounds of latex per hour employs as pipe 59 three-inch diameter stainless steel Schedule 40 pipe. A tube, such as tube 69, is about one inch in diameter. The conduit 61 is a stainless steel reducer from three-inch to two-inch pipe. The valve 62 is a nominal two-inch pipe size and the disentrainment chamber 64 is about eighteen inches in diameter, and operated at about atmospheric pressure. A plurality of latexes were prepared. The resultant latex solids containing 41 percent by weight styrene, 20 weight percent acrylonitrile and 39 percent butadiene. The latex particle size was about 1600 angstroms in diameter and the latexes were about 31 weight percent solids.
A range of operating conditions were employed. The range and the average values for about fifty batches of latex are set forth in Table I.
TABLE I______________________________________OPERATING CONDITIONS MEANPARAMETER UNITS VALUE RANGE______________________________________Latex Feed Rate lb/hr 2350 1200-4400Coagulation Temp. °C. 65 93-60Hydroset Backpressure psig 60 55-75Hydroset Temp. °C. 119 86-148Expeller Output lb/hr 727 250-850Pressed CakeOutlet Moisture wt % 19 10-20______________________________________
A plurality of latexes were prepared wherein the polymer composition of the latex was 46 weight percent butadiene, 17 percent acrylonitrile and 37 percent styrene. The butadiene latex was prepared and the styrene acrylonitrile grafted thereon to provide latexes having about 37 weight percent solids and a particle size of about 1400 angstroms. The latex was coagulated at 37 percent solids and diluted in the mixing and forwarding apparatus to about 26 to 32 percent solids in order to provide a more flowable paste. The range of operating conditions and the mean values are set forth in Table II.
TABLE II______________________________________OPERATING CONDITIONS MEANPARAMETER UNITS VALUE RANGE______________________________________Latex Feed Rate* lb/hr 2210 900-3700Coagulation Temp. °C. 46 38-66Hydroset Backpressure psig 35 10-80Hydroset Temp. °C. 95 70-115Expeller Output lb/hr 500 280-580Pressed CakeOutlet Moisture wt % 11.8% 9-14______________________________________ *Coagulated paste diluted to approximately 26 to 32% solids by weight prior to mixing and hydrosetting.
In a manner similar to the foregoing, other synthetic resinous thermoplastic latexes are readily coagulated and dewatered.
As is apparent from the foregoing specification, the present invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. For this reason, it is to be fully understood that all of the foregoing is intended to be merely illustrative and is not to be construed or interpreted as being restrictive or otherwise limiting of the present invention, excepting as it is set forth and defined in the hereto-appended claims. | Latex is shear coagulated to form a paste, the paste heated and sheared to form a desired crumb; the crumb is mechanically dewatered and ground to a desired particle size. Relatively low energy consumption is a feature of the process. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for manufacturing ultrasonic transducer, in particular to a method for manufacturing micro capacitive ultrasonic transducer. In detail, the present invention employs the nanoimprint lithography method to manufacture the micro capacitive ultrasonic transducer.
BACKGROUND OF THE INVENTION
[0002] The technology of ultrasonic inspection has been developed since the World War II. In the beginning, it is used for the national defense and the military affairs. Until 1950s, the ultrasonic inspection technology started to be widely employed on the medical treatments. In the area of the ultrasonic inspection, ultrasonic transducer plays a very important role thus attracting the industry/government/academia to plunge into the research in the past decades, and the related technologies are also getting more and more mature now. Among all the ultrasonic transducers, the piezoelectric transducer was kept the main stream for a long time.
[0003] The so-called piezoelectric effect includes both of the direct piezoelectric effect and the converse piezoelectric effect. Under the direct piezoelectric effect, a piezoelectric body, when put into an electric field, will be elongated along the direction of the electric field according to the elongating of the electrical dipole moment thus transferring the mechanical energy into electric energy. On the contrary, under the converse piezoelectric effect, if the piezoelectric body was pressed, the electrical dipole moment thereof will be shortened. In order to resist this tendency, the piezoelectric body thus will induce voltage for trying to keep the original state. With such character, the piezoelectric transducer transfers the electrical signals into the sonic signals, and also can transfer the sonic signals into the electrical signals thus being able to regard as a probe in the ultrasonic inspection. The common material of the piezoelectric body can be the ceramic, such as BaTiO3 and PZT, and the single crystal materials, such as quartz, tourmaline, tantalates, and columbate. However, the piezoelectric transducer still exit some disadvantages, for example the cost of such piezoelectric transducer is too high, and the oscillation of the crystal lattice will easily debase the bandwidth and the sound pressure. Moreover, the difference between the impedances of the piezoelectric material and that of the air is so large as to cause the unmatched phenomenon thus resulting in large reflection of the sonic signals in the contact interface and diminish the inspection efficiency. In addition, for the limitation of the resolution and the bandwidth, the piezoelectric transducer is hardly to be used for the precise inspection in nano-level.
[0004] Instead of the piezoelectric transducer, the micro capacitive ultrasonic transducer has become the main stream of the ultrasonic transducer research. The related patents have also been gradually accumulated recently, such as U.S. Pat. No. 6,426,582, U.S. Pat. No. 6,004,832, and U.S. Pat. No. 6,295,247 and so on. Please refer to FIG. 1 , which shows the basic structure of the micro capacitive ultrasonic transducer. A plurality of the support pedestals 12 is formed on the substrate 11 , and the oscillation film 13 with an upper electrode 14 thereon is formed on the support pedestal 12 . Wherein, the substrate 14 doped with impurities to get conductivity is used to be the lower electrode for forming a capacitance structure with the upper electrode 14 . The oscillation cavity 15 composed of the substrate 11 , the support pedestal 12 , and the oscillation film 13 is used to provide the space for oscillation when the oscillation film 13 is vertically oscillating. Such micro capacitive ultrasonic transducer possesses the following merits: (1) larger bandwidth; (2) easily to form large density array; (3) simply to be integrated with the front-end circuits on the same wafer; and (4) being able to largely manufacture thus reducing the cost.
[0005] In fact, the important character of the micro capacitive ultrasonic transducer is the design of the oscillation cavity and the oscillation film, so the geometric parameters of the oscillation cavity and the oscillation film, such as the radius and the thickness of the oscillation film and the distance between the upper electrode and the lower electrode, are rigidly related to the efficiency of the ultrasonic transducer. Therefore, it is very important to control all of such geometric parameters more stably and more uniformly in the manufacturing process. Please refer to FIG. 2A to 2 C, which are the schematic views showing the traditional method for manufacturing the micro capacitance ultrasonic transducer of the prior art. Firstly, a substrate 21 is provided, and then a support film 22 , an oscillation film 23 and a conductive layer 24 are successively formed on the substrate 21 . A plurality of holes 25 that penetrates the oscillation film 23 and the conductive layer 24 then is 1 o generated after the procedure of photolithography and etching. Finally, through the plurality of holes 25 , the support film 22 can be etched to form a plurality of oscillation cavities 221 thereon. Because of the character that the selectivity of the etching rate on the support film 22 and the oscillation film 23 is different, the etching solution that preferentially etches the support film 22 rather than the oscillation film 23 is used to form a plurality of oscillation cavities 221 thus completing the whole ultrasonic transducers. Wherein, the shape of the oscillation cavities 221 is approximate cylinder that expanded from the center of the holes 25 . However, such method is hardly to control the precise shape of the oscillation cavities and cannot provide the check mechanism. It only depends on the experience so that many vibrations in the process, such as the variation of the etching solution concentration, will very easily cause the variation of the geometrical size of the oscillation cavities 221 further affecting the character of the whole transducers.
[0006] Moreover, the plurality of holes 25 used for the entries of the etching solution and the exits of the etching by-products will easily cause the contamination of the oscillation cavities 221 , remaining certain residues on the wall of the cavities thus affecting the characters of the transducer. The present invention thus provides a new method not only for overcoming the aforesaid disadvantages but also for improving the character of the ultrasonic transducers.
SUMMARY OF THE INVENTION
[0007] The primary object of the present invention is to provide an imprint method for manufacturing micro capacitive ultrasonic transducer. The method employs a particularly patterned mold to form the oscillation cavities of micro capacitance ultrasonic transducer thus obtaining the purposes of large batch manufacturing, uniform control, and cost reduction.
[0008] The secondary object of the present invention is to precisely control the size of the oscillation cavities of micro capacitive ultrasonic transducer, reducing the distance between the top and the bottom electrodes thus increasing the sensitivity of the ultrasonic transducer.
[0009] The third object of the present invention is to provide an imprint method for manufacturing micro capacitive ultrasonic transducer, which can improve the cleanness of the oscillation cavities without generating entry holes in the prior art that provide the entries of the etching liquid and the exits of the byproducts.
[0010] In order to achieve the aforesaid objects, the present invention provides an imprint method for manufacturing ultrasonic transducer, including the following steps:
a) Providing a substrate with electric conductance. b) Forming a support film layer on the substrate. c) Providing a mold with a patterned surface, wherein the patterned surface having an array pattern with projections and recesses arranged in order. d) Imprinting the mold into the support film layer with the patterned surface thus transferring the array pattern into the support film layer. e) Removing the mold, a plurality of recessions corresponding to the array pattern thus formed within the support film layer. f) Providing a polymer film, the polymer film having an obverse side and a reverse side g) Forming a plurality of upper electrodes corresponding to the recessions and a plurality of conductor lines between any two adjoining upper electrodes on the polymer film. h) Sticking the reverse side of the polymer film onto the support film layer to seal the recessions and become a plurality of cavities thus completing a plurality of ultrasonic transducers.
[0019] In order to achieve the aforesaid objects, the present invention also provides another method including the following steps:
a) Providing a substrate with electric conductance. b) Forming a support film layer on the substrate. c) Providing a cylindrical mold with a patterned outer surface, the patterned outer surface having an array pattern with projections and recesses arranged in order. d) Rotating the cylindrical mold over the support film layer thus transferring the array pattern into the support film layer, forming a plurality of recessions. e) Providing a polymer film, the polymer film having an obverse side and a reverse side f) Forming a plurality of upper electrodes corresponding to the recessions on the polymer film and a plurality of conductor lines between any two adjoining upper electrodes. g) Sticking the reverse side of the polymer film onto the support film layer to seal the recessions and become a plurality of cavities thus completing a plurality of ultrasonic transducers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is the schematic view showing the basic structure of the micro capacitive ultrasonic transducer.
[0028] FIG. 2A to FIG. 2C are the schematic views showing the method for manufacturing the micro capacitive ultrasonic transducer in the prior arts.
[0029] FIG. 3A to FIG. 3E are the schematic views showing the nanoimprint lithography method applied in the semiconductor process.
[0030] FIG. 4A to FIG. 4G are the schematic views showing the first embodiment of the present invention.
[0031] FIG. 4H is the top view of the micro capacitive ultrasonic transducer of the present invention.
[0032] FIG. 5A to FIG. 5G are the schematic views showing the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Matched with corresponding drawings, the preferable embodiments of the invention are presented as following and hope they will benefit your esteemed reviewing committee members in reviewing this patent application favorably.
[0034] Nanoimprint lithography has developed since 1996 when Dr. Stephen Y. Chou published the related papers. Nanoimprint lithography is quiet different from the traditional lithography in semiconductor process; it does not need to use any energy beams, so the resolution in nanoimprint lithography will not be limited by the phenomenon of diffraction, scattering, and interference when optical wave entering into the photoresist and by the effect of back scattering from the substrate. In fact, the imprint method was disclosed at least as early as in 1970s, and the related researches as well as lots of the related patents have been accumulated, such as U.S. Pat. No. 4,035,226, U.S. Pat. No. 5,259,926, U.S. Pat. No. 5,772,905, and U.S. Pat. No. 6,375,870.
[0035] Please refer to FIG. 3A to FIG. 3E , which are the schematic views showing the technology of nanoimprint lithography applied in the semiconductor manufacturing process. Firstly, an isolation film 32 and a flexible film 33 keeping the state of plasticity are successively formed on a substrate 31 . Then a mold 34 with relative projection and recess patterns formed on the surface thereof is pressed into the flexible film 33 thus transferring the pattern into the flexible film 33 . In the process of imprinting, the projection portion of the patterned surface will not directly touch to the isolation film 32 thus forming a relative thin region 331 above the isolation film 32 and generating a relative high-low pattern corresponding to the pattern on the mold surface. Then, the relative thin region 331 is removed by the method of etching to reveal a partial isolation region 321 under the thin region 331 . Finally, the partial isolation region 321 and the flexible film 33 are removed, and then the remaining portion of the isolation film 32 corresponding to the mold surface pattern can be used as the mask for the follow-up steps in semiconductor process such as ion implantation.
[0036] Obviously, the nanoimprint lithography employed in the semiconductor manufacturing process can save quiet a number of process steps. Moreover, the using of the mold not only accelerates the manufacture procedure, but also saves the high cost of the mask fabricating and maintaining. Besides, the array pattern is so practicable in mold manufacturing that nanoimprint lithography technology can be easily applied to the ultrasonic transducer manufacturing, providing the quiet innovation of the industry. The advantages of the nanoimprint lithography technology are:
1) Volume manufacturing. 2) Lower cost. 3) Variety choices of the polymer materials used for the oscillation film and the oscillation cavity, such as Bio-compatible material, which makes the micro capacitive ultrasonic transducer more beneficial to apply in the biomedical science. 4) Shorting the height of the oscillation cavity and well controlling the uniformity thus improving the sensitivity of the ultrasonic transducer. 5) Employing the polymer material, instead of the silicon, in the oscillation cavity thus diminishing the effect of Lamb wave. 6) Unifying the materials of the oscillation film and the oscillation cavity, which are different in the conventional process and cause the different expansion coefficient, to overcome the problem of the stability of the transducer. 7) Precisely controlling the size of the ultrasonic transducer in micro or even nano level thus improving the efficiency of the transducer and enlarging the application thereof.
[0044] FIG. 4A to FIG. 4G are the schematic views showing the first embodiment of the present invention. As shown in the figures, the substrate 41 doped with impurity for electric conductivity is provided as the lower electrode of the ultrasonic transducer. In the preferable embodiment for strengthening the lower electrode, a plurality of conductive plates can be formed on the substrate 41 ; wherein between any two of the adjoining plates is connected with a conductor line. Then, a support film layer 42 is formed on the substrate 41 . To operate in the nanoimprint technology, the material of the support film layer 42 has to be a flexible polymer such as PMMA. In order to improve the sensitivity of the ultrasonic transducer, the support film layer 42 used to be the wall of the oscillation cavities of the transducer is better to be controlled as thin as possible. Further, a mold 51 with a patterned surface 511 is provided, and wherein the patterned surface 511 has an array pattern 512 with projections and recesses arranged in order. By using a driving apparatus, the mold 51 can be imprinted into the support film layer 42 with the patterned surface 511 thus transferring the array pattern 512 to the support film layer 42 . After removing the mold 51 , a plurality of recessions 421 corresponding to the array pattern 512 thus is formed on the support film layer 42 . In the process of imprinting, the projection portion of the patterned surface will not directly touch to the surface of substrate 41 ; in other words, the bottom of the recessions 421 formed by the mold 51 will not touch to the substrate 41 thus remaining a relative thin region above the substrate 41 . Next, the relative thin region is removed by using the method of etching to reveal the substrate 41 on the recession bottom. Such method can prevent the mold from damaging the surface thereof and the substrate surface. Besides, the imprint method can be hot stamping, laser imprint, nanoimprint, and any other technologies that can generate the imprint-like effect.
[0045] Next, a polymer film 43 is provided on a platform, and a plurality of particularly arranged upper electrode plates 441 is formed on the polymer film 43 . The upper electrode plate 441 is used as the upper electrode of the capacitive ultrasonic transducer, and between any two of the adjoining upper electrode plates is connected with a conductor line. Finally, the polymer film 43 with the upper electrode plates 441 thereon is stuck on the support film layer 42 thus sealing the recessions 421 becoming a plurality of closed cavities 422 . Wherein the materials of the polymer film 43 and the support film layer 42 can be the same, which can prevent the problem of different expansion coefficient resulting in the instability of the ultrasonic transducer. On the closed cavities 422 is the polymer film 43 , and on the polymer film 43 is the plurality of upper electrode plates 441 ; wherein the upper electrode plates are respectively corresponding to the closed cavities 422 . Please refer to FIG. 4H , which is the top view showing the micro capacitive ultrasonic transducer of the present invention. The upper electrode plates 441 are respectively located onto the central area of the corresponding closed cavities 422 , and the cross section area of the upper electrode plate 441 is about 60%˜70% of that of the closed cavity 422 ; besides, between any two of the adjoining electrode plates is connected with a conductor line.
[0046] Moreover, the formation of the aforesaid upper electrode plates 441 can be the traditional semiconductor manufacturing process, including the following steps:
1) Forming a conductive layer 44 on a polymer film 43 , then coating a photoresist film on the conductive layer 44 . 2) Using photolithography technology to form a photoresist mask arranged in order on the photoresist film. 3) Etching the conductive layer 44 to form the upper electrode plates 441 corresponding to the photoresist mask.
Such method is employed when the material of conductive layer 44 is solid film, such as metal film or polycide. But if the material of conductive layer 44 is a flexible material, the nanoimprint technology can also be employed in the formation of the upper electrode plates 441 , including the following steps:
1′) Forming a conductive layer 44 onto the polymer film 43 . 2′) Proving a second mold with a patterned surface, wherein the patterned surface having a second array pattern with projections and recesses arranged in order. 3′) Imprinting the second mold into the conductive film 44 thus transferring the second array pattern to the surface of the conductive film 44 . 4′) Removing the second mold, a plurality of the upper electrode plates 441 thus being formed on the polymer film 43 .
[0054] Please refer to FIG. 5A to FIG. 5G , which are the schematic views showing the second preferable embodiment of the present invention. First, the substrate 61 doped with impurity for electric conductivity is provided as the lower electrode of the ultrasonic transducer. In the preferable embodiment for strengthening the lower electrode, a plurality of conductive plates can be formed on the substrate 61 , and between any two of the adjoining plates is connected with a conductor line. Then a support film layer 62 is formed on the substrate 61 . To operate in the nanoimprint technology, the material of the support film layer 62 has to be a flexible polymer, such as PMMA. Then, a cylindrical mold 71 with an array pattern 712 formed on the outer surface thereof is provided to press to and roll across the support film layer 62 thus forming a plurality of the particularly arranged recessions 621 on the support film layer 62 . Similarly, in the rolling process of the cylindrical mold 71 , the projection portion of the mold outer surface will not touch to the surface of the substrate 61 . In other words, the bottom of the recessions 621 formed by the mold 71 will not touch to the substrate 61 thus remaining a relative thin region above the substrate 61 . Next, removing the relative thin region by the etching method to reveal the portion of the substrate 61 .
[0055] Next, a polymer film 63 is provided on a platform, and a plurality of particularly arranged upper electrode plates 641 is formed on the polymer film 63 . The upper electrode plate 641 is used as the upper electrode of the capacitance ultrasonic transducer, and between any two of the adjoining upper electrode plates is connected with a conductor line. Finally, the polymer film 63 with the upper electrode plates 641 thereon is stuck on the support film layer 62 thus sealing the recessions 621 becoming a plurality of closed cavities 622 . Wherein, on the closed cavities 622 is the polymer film 63 , and on the polymer film 63 is the plurality of upper electrode plates 641 corresponding to the closed cavities 622 . The upper electrode plates 641 are respectively located onto the central area of the corresponding closed cavities 622 , and the cross section area of the upper electrode plate 641 is about 60%˜70% of that of the closed cavity 622 ; besides, between any two of the adjoining electrode plates is connected with a conductor line.
[0056] In addition, as described in the first embodiment of the present invention, the formation of the upper electrode plates 641 can be the tradition semiconductor manufacturing process if the material of the conductive film is solid film, such as metal film or polycide. However, if the material of the conductive film is also the flexible material, the imprint method thus can be employed, such as hot stamping, laser imprint, nanoimprint, the imprint methods described in the aforesaid two embodiments, and any other technologies that can generate the imprint-like effect.
[0057] Moreover, the formation of the upper electrode plates both in the first and the second embodiment can be carried out after the polymer film stuck onto the support film layer. In other words, after forming a plurality of recessions of the support film layer on the substrate, the polymer film can be struck onto the support film layer in advance thus sealing the plurality of recessions to become a plurality of the closed cavities for micro capacitive ultrasonic transducer. Finally, a plurality of the upper electrode plates corresponding to the closed cavities is formed on the polymer film thus completing a plurality of the micro capacitive ultrasonic transducers.
[0058] Although the present invention has been described with reference to a preferred embodiment, it should be appreciated that various modifications and adaptations can be made without departing from the scope of the invention as defined in the claims.
[0059] In summary, from the structural characteristics and detailed disclosure of each embodiment according to the invention, it sufficiently shows that the invention has progressiveness of deep implementation in both objective and function, also has the application value in industry, and it is an application never seen ever in current market and, according to the spirit of patent law, the invention is completely fulfilled the essential requirement of new typed patent. | The present invention relates to an imprint method for manufacturing micro capacitive ultrasonic transducer, which uses a mold with a particularly patterned surface to imprint into a flexible material thus forming the oscillation cavities of the ultrasonic transducer. Such imprint method not only realizes the volume manufacturing and reduces the cost, but also can precisely control the geometrical size of the oscillation cavities and thus shorten the distance between the upper and the lower electrodes to the micro/nano level, largely improving the sensitivity of the transducer. Moreover, the present invention further changes the procedure for manufacturing micro capacitive ultrasonic transducer of the prior art, which can both save the process steps and overcome the disadvantages in the prior art. | 8 |
This is a division of application Ser. No. 771,222 filed Feb. 23, 1977, now abandoned.
BRIEF SUMMARY OF THE INVENTION
The invention relates to thiobenzamides characterized by the formula ##STR3## wherein X' is bromine, fluorine, iodine, trifluoromethyl or C 3-4 alkyl or pharmaceutically acceptable acid addition salts thereof.
In another aspect, the invention relates to pharmaceutical preparations having mono-amine oxidase inhibiting activity comprising a compound of the formula ##STR4## wherein X is halogen, trifluoromethyl or C 3-4 alkyl or a pharmaceutically acceptable acid addition salt thereof.
In still another aspect, the invention relates to the use of the compounds of formula I as agents in the treatment of depression, i.e., as antidepressants.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, thiobenzamides of the formula ##STR5## wherein X is halogen, trifluoromethyl or C 3-4 alkyl and pharmaceutically acceptable acid addition salts thereof have been found to possess monoamine oxidase (MAO) inhibiting activity.
More specifically, in one aspect the invention relates to pharmaceutical preparations having MAO inhibiting activity, said preparations containing as an essential active ingredient a compound of formula I hereinbefore or a pharmaceutically acceptable acid addition salt thereof.
In another aspect, the invention relates to a method of treating depressive conditions with a compound of the formula ##STR6## wherein X is halogen, trifluoromethyl or C 3-4 alkyl or a pharmaceutically acceptable acid addition salt thereof.
The invention also relates to compounds characterized by the formula ##STR7## wherein X' is bromine, fluorine, iodine, trifluoromethyl or C 3-4 alkyl or pharmaceutically acceptable acid addition salts thereof.
The term "halogen" denoted by X is chlorine, fluorine, bromine or iodine with chlorine being preferred. C 3-4 alkyl is a straight-chain or branched-chain alkyl group containing 3 or 4 carbon atoms, namely, n-propyl, isopropyl, n-butyl, isobutyl, 1-methylpropyl or t-butyl.
The thiobenzamide of formula I wherein X is chlorine, namely, p-chloro-N-(2-morpholinoethyl)thiobenzamide, is a known compound which is described in French Pat. No. 1,501,846.
The thiobenzamides of formula I form addition salts at the nitrogen atom of the morpholino residue with organic or inorganic acids. Exemplary of such salts are hydrohalides, for example, hydrochlorides; phosphates; alkylsulfonates, for example, ethanesulfonates; monoarylsulfonates, for example, toluenesulfonates; acetates; citrates; benzoates and the like.
Preferred thiobenzamides of formula I are those in which X is halogen.
An especially preferred thiobenzamide of formula I is p-chloro-N-(2-morpholinoethyl)-thiobenzamide.
Other preferred thiobenzamides of formula I are p-bromo-N-(2-morpholinoethyl)thiobenzamide and p-t-butyl-N-(2-morpholinoethyl)-thiobenzamide.
The thiobenzamides of formula I' hereinbefore and their acid addition salts can be prepared by reacting N-(2-aminoethyl)-morpholine with a compound of the formula ##STR8## wherein X' is as previously described and Y is methoxy or ethoxy and, if desired, converting a thiobenzamide of formula I' obtained into a pharmaceutically acceptable acid addition salt thereof.
The reaction of N-(2-aminoethyl)-morpholine with a compound of formula II is conveniently carried out in the absence of solvent at a temperature in the range of from about room temperature to about 140° C., preferably at about 90° C.
The compounds of formula II are known compounds or are analogs of known compounds and can be prepared by known procedures. Thus, for example, a benzonitrile of the formula ##STR9## wherein X' is as previously described can be reacted in the presence of hydrogen chloride gas with methanol or ethanol to give the hydrochloride of the corresponding benzimidate of the formula ##STR10## wherein X' and Y are as previously described. Then, the resulting hydrochloride can be converted into the desired compound of formula II with hydrogen sulfide in the presence of pyridine.
As mentioned earlier, the thiobenzamides of formula I and their pharmaceutically acceptable acid addition salts possess monoamine oxidase (MAO) inhibiting activity. Due to this activity, the thiobenzamides of formula I and their pharmaceutically acceptable acid addition salts are useful in the treatment of depressive conditions. Stated another way, the compounds of formula I are useful as antidepressants.
The MAO inhibiting activity of the thiobenzamides of formula I can be demonstrated using standard methods. Thus, the thiobenzamides of formula I to be tested were administered p.o. to rats. One hour after the administration, the rats were killed and the MAO inhibiting activity in the liver homogenates was measured according to the method in Biochem. Pharmacol. 12, pp. 1439-1441 (1963). The thus determined activity of representative thiobenzamides of formula I as well as their toxicity is evident from the ED 50 values (μmol/kg, p.o. in the rat) or LD 50 values (mg/kg, p.o. in the mouse) listed in the Table which follows:
TABLE______________________________________Thiobenzamide ED.sub.50 LD.sub.50______________________________________p-Chloro-N-(2-morpholinoethyl)-thiobenz- 2 1250-2500 amidep-Bromo-N-(2-morpholinoethyl)-thiobenz- 2 1250-2500 amidep-t-Butyl-N-(2-morpholinoethyl)-thiobenz- 10 >5000 amide______________________________________
The thiobenzamides of formula I and their pharmaceutically acceptable acid addition salts can be used as medicaments, for instance, in the form of pharmaceutical preparations which contain them in association with a pharmaceuticaly acceptable carrier material. Such carrier material can be an organic or an inorganic inert carrier material which is suitable for enteral, for example, oral, or parenteral administration, such as water, gelatin, gum arabic, lactose, starch, magnesium stearate, talc, vegetable oils, polyalkyleneglycols or the like. The pharmaceutical preparations can be made up in solid form, for example, as tablets, dragees, suppositories or capsules, or in liquid form, for example, as solutions, suspensions or emulsions. The pharmaceutical preparations may be sterilized and/or may contain compatible adjuvants such as preservatives, stabilizing agents, wetting or emulsifying agents, salts for modifying the osmotic pressure or buffering agents. The pharmaceutical preparations may also contain other therapeutically valuable materials.
Appropriate pharmaceutical dosage forms contain from about 1 mg. to 100 mg. of a thiobenzamide of formula I or of a pharmaceutically acceptable acid addition salt thereof. Appropriate oral dosage ranges are from about 0.1 mg/kg per day to about 5 mg/kg per day. Appropriate parenteral dosage ranges are from about 0.01 mg/kg per day to about 0.5 mg/kg per day. These ranges can be increased or decreased according to individual requirements and the directions of the attending physician. Oral administration is preferred.
The examples which follow further illustrate the present invention. All temperatures are in degrees Centigrade, unless otherwise stated.
EXAMPLE 1
Preparation of p-t-butyl-N-(2-morpholinoethyl)-thiobenzamide
10.6 g. of O-ethyl-p-t-butyl-thiobenzoate and 6.2 g. of N-(2-aminoethyl)-morpholine are heated at 90° C. for 2 hours. Then, the mixture is cooled to room temperature, treated with 50 ml. of ice-water and, while cooling with ice-water and stirring, is acidified with 3-N hydrochloric acid. Thereafter, the solution is extracted with two 100 ml. portions of diethyl ether and the aqueous phase is made basic with ammonia while cooling with ice-water and stirring. The crystalline product is removed by filtration and washed with cold water and diethyl ether. After recrystallization from ethyl acetate/hexane, there is obtained 6.7 g. of p-t-butyl-N-(2-morpholinoethyl)-thiobenzamide having a melting point of 129° C.
The O-ethyl-p-t-butyl-thiobenzoate used as the starting material can be prepared as follows:
A solution of 41.2 g. of p-t-butylbenzonitrile in 450 ml. of absolute ethanol is saturated with hydrogen chloride gas while cooling with ice-water and then is left to stand overnight at 4° C. Thereafter, the mixture is evaporated to dryness and the residue further evaporated with three 300 ml. portions of ethanol. The solid residue is triturated with 500 ml. of diethyl ether and filtered. After recrystallization from ethanol/diethyl ether, there are obtained 56.1 g. of ethyl p-t-butylbenzimidate hydrochloride having a melting point of 116° C.
25 g. of ethyl p-t-butylbenzimidate hydrochloride are dissolved in 65 ml. of pyridine saturated with hydrogen sulfide. Hydrogen sulfide is subsequently conducted through the solution for 6 hours while cooling with ice-water. The mixture is allowed to stand overnight at 4° C. While cooling with ice-water and stirring, the mixture is subsequently treated successively with 50 ml. of ice-water, 90 ml. of concentrated hydrochloric acid and 90 g. of ice and then extracted with three 200 ml. portions of diethyl ether. The ether solution is washed with hydrochloric acid, dried over potassium carbonate, evaporated and distilled (100° C., 0.04 Torr), and there are obtained 21 g. of O-ethyl-p-t-butyl-thiobenzoate.
EXAMPLE 2
Preparation of p-bromo-N-(2-morpholinoethyl)-thiobenzamide hydrochloride
6.1 g. of O-ethyl-p-bromo-thiobenzoate and 3.25 g. of N-(2-aminoethyl)-morpholine are heated at 90° C. for 2 hours. Then, the mixture is cooled to room temperature, treated with 25 ml. of ice-water and, while cooling with ice-water and stirring, acidified with 3-N hydrochloric acid. The precipitated product is then removed by filtration and washed with water and diethyl ether. After recrystallization from methanol, there are obtained 3.7 g. of p-bromo-N-(2-morpholinoethyl)-thiobenzamide hydrochloride having a melting point of 231° C.
EXAMPLE 3
Tablets of the following composition are prepared in a manner known per se:
______________________________________p-chloro-N-(2-morpholinoethyl)-thiobenzamide 50.0 mg.Lactose 95.0 mg.Maize starch 100.0 mg.Talc 4.5 mg.Magnesium stearate 0.5 mg.Weight of one tablet 250.0 mg.______________________________________
In place of p-chloro-N-(2-morpholinoethyl)-thiobenzamide, there can also be used, for example, as the active ingredient, p-bromo-N-(2-morpholinoethyl)-thiobenzamide or p-t-butyl-N-(2-morpholinoethyl)-thiobenzamide. | Thiobenzamides of the formula ##STR1## wherein X' is bromine, fluorine, iodine, trifluoromethyl or C 3-4 alkyl prepared from N-(2-aminoethyl)-morpholine and a compound of the formula ##STR2## wherein X' is as hereinbefore set forth and;
Y is methoxy or ethoxy are described. The end products, including p-chloro-N-(2-morpholinoethyl)-thiobenzamide, are useful in the treatment of depressive conditions, that is, are useful as antidepressants. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US National Stage of International Application No. PCT/EP2008/052324, filed Feb. 26, 2008 and claims the benefit thereof. The International Application claims the benefits of European application No. 07005303.8 EP filed Mar. 14, 2007, European application No. 07007925.6 EP filed Apr. 18, 2007, and European application No. 07011676.9 EP filed Jun. 14, 2007, all of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to solder alloys and to a process for repairing a component.
BACKGROUND OF THE INVENTION
It is sometimes necessary to repair components after they have been produced, for example after casting or after they have been used and cracks have formed.
There are various repair processes for this purpose, for example the welding process; in this process, however, it is additionally necessary to melt a substrate material of the component, and this may result in damage particularly to cast and directionally solidified components and in the evaporation of constituents of the substrate material.
A soldering process is carried out at temperatures which are lower than the temperature for the welding process and therefore lower than the melting temperature of the substrate material.
Nevertheless, the solder should have high strength in order that the crack filled with solder or the depression does not weaken the entire component at the high operating temperatures.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a solder alloy and a process for repairing a component which overcome the problem mentioned above.
The object is achieved by a solder consisting of a solder alloy and by a process as claimed in the independent claims.
The solder alloy comprises:
gallium (Ga) and/or germanium (Ge), and
optionally
chromium (Cr),
cobalt (Co),
aluminum (Al),
tungsten (W),
nickel (Ni),
and has one of the following compositions,
where G=Ga and/or Ge:
Ni—Cr-G, Ni—Co-G,
Ni—W-G, Ni—Al-G,
Ni—Cr—Co-G,
Ni—Cr—W-G,
Ni—Cr—Al-G,
Ni—Co—W-G,
Ni—Co—Al-G,
Ni—W—Al-G,
Ni—Cr—Co—W-G,
Ni—Cr—Co—Al-G,
Ni—Cr—W—Al-G,
Ni—Co—W—Al-G,
Ni—Cr—Co—W—Al-G.
The dependent claims list further advantageous measures which can advantageously be combined with one another in any desired way, theses measures are the following:
the solder alloy does not contain any silicon, the solder alloy does not contain any carbon, the solder alloy does not contain any iron, the solder alloy does not contain any manganese, the solder alloy comprises gallium (Ga) and no germanium (Ge), the solder alloy comprises germanium (Ge) and no gallium (Ga), the solder alloy comprises gallium (Ga) and germanium (Ge), in the solder alloy, the gallium (Ga) or germanium (Ge) content is ≧3% by weight, in particular the gallium or germanium content is 3% by weight, in the solder alloy, the gallium (Ga) or germanium (Ge) content is ≧6% by weight, in particular the gallium or germanium content is 6% by weight, in the solder alloy, the gallium (Ga) or germanium (Ge) content is ≦28% by weight, in particular the gallium or germanium content is ≦18% by weight, in the solder alloy, the gallium (Ga) or germanium (Ge) content is ≦13% by weight, in particular the gallium or germanium content is 13% by weight, in the solder alloy, the gallium (Ga) or germanium (Ge) content is ≦8% by weight, in particular the gallium or germanium content is 8% by weight, the solder alloy comprises 18% by weight to 28% by weight, in particular 20% by weight, germanium (Ge), especially 26% by weight Ge, the solder alloy comprises 21% by weight to 25% by weight germanium (Ge), in particular 23% by weight germanium (Ge), the solder alloy comprises 28% by weight to 35% by weight gallium (Ga), the solder alloy contains chromium (Cr), in particular at least 0.1% by weight, the solder alloy contains cobalt (Co), in particular at least 0.1% by weight, the solder alloy contains aluminum (Al), in particular at least 0.1% by weight, the solder alloy contains tungsten (W), in particular at least 0.1% by weight, the solder alloy contains titanium (Ti), in particular at least 0.1% by weight, the solder alloy contains molybdenum (Mo), in particular at least 0.1% by weight, the solder alloy contains tantalum (Ta), in particular at least 0.1% by weight, the solder alloy consists of nickel (Ni) and gallium (Ga) or germanium (Ge) and a single further alloying element selected exclusively from the group consisting of chromium (Cr), cobalt (Co), tungsten (W) and aluminum (Al), the solder alloy consists of nickel (Ni) and gallium (Ga) or germanium (Ge) and two further alloying elements selected exclusively from the group consisting of chromium (Cr), cobalt (Co), tungsten (W) and aluminum (Al), the solder alloy consists of nickel (Ni) and gallium (Ga) or germanium (Ge) and three further alloying additions selected exclusively from the group consisting of chromium (Cr), cobalt (Co), tungsten (W) and aluminum (Al), the solder alloy consists of nickel (Ni), chromium (Cr), cobalt (Co), tungsten (W), aluminum (Al) and gallium (Ga) or germanium (Ge), the solder alloy does not contain any boron (B) and/or any zirconium (Zr), the solder alloy comprises nickel (Ni) as the highest proportion by weight, the solder alloy comprises nickel (Ni) as the highest proportion by volume, in the solder alloy, the chromium content is 2% by weight-10% by weight, in particular 3% by weight-9% by weight, especially 8% by weight, in the solder alloy, the aluminum content is 1% by weight-5% by weight, in particular 2% by weight-4% by weight, especially 3% by weight, in the solder alloy, the tungsten content is 2% by weight-6% by weight, in particular 3% by weight-5% by weight, especially 4% by weight, in the solder alloy, the cobalt content is 2% by weight-10% by weight, in particular 3% by weight-9% by weight, especially 8% by weight, the solder alloy does not contain any silicon, the solder alloy does not contain any carbon, the solder alloy does not contain any iron, the solder alloy does not contain any manganese, the solder alloy does not contain any tungsten, in the solder alloy, the aluminum content is between 1.0% by weight and 2.0% by weight, in particular 1.5% by weight, in the solder alloy, the tungsten content is between 1% by weight and 3% by weight, in particular 2% by weight, in the solder alloy, the cobalt content is between 3% by weight and 5% by weight, in particular 4% by weight, in the solder alloy, the chromium content is between 3% by weight and 5% by weight, in particular 4% by weight, in the solder alloy, the solder alloy does not comprise any chromium (Cr), in the solder alloy, the solder alloy does not comprise any cobalt (Co), in the solder alloy, the solder alloy does not comprise any aluminum (Al), in the solder alloy, the solder alloy consists of nickel, germanium, tungsten and aluminum, in the solder alloy, the solder alloy consists of nickel, germanium, cobalt and tungsten, in the solder alloy, the solder alloy consists of nickel, germanium, chromium and tungsten, in the solder alloy, the solder alloy consists of nickel, germanium, chromium and cobalt, in the solder alloy, the solder alloy consists of nickel, germanium, cobalt and aluminum, in the solder alloy, the solder alloy consists of nickel, germanium, chromium and aluminum.
The process comprises repairing a component using a solder at a temperature of at least 1140° C., especially at least 1160° C.
The dependent claims list further advantageous measures for the process which can advantageously be combined with one another in any desired way, these measures are the following:
the soldering process is carried out under isothermal conditions, the soldering process is carried out by means of a temperature gradient, the solder is directionally solidified, in particular in single crystal form, the solder is used for the alloys PWA 1483, PWA 1484 or Rene N5, a substrate of the component is directionally solidified, in particular in single crystal form, the temperature is 1160° C., the temperature is 1180° C., the temperature is 1200° C., the temperature is 1230° C., the temperature is 1260° C., the temperature is 1280° C., the temperature is at most 1280° C., in particular at most 1160° C., an overall pressure of less than 10 mbar (1000 Pa), in particular of about 1 mbar (100 Pa), is set in a process chamber, the overall pressure in the process chamber is set at more than 0.1 mbar (10 Pa), in particular at more than 1 mbar (100 Pa), the process chamber is purged with an inert gas, in particular for at least 10 hours, in particular preferably for 48 hours, before the component is heated in the process chamber with the solder, the throughput of the purging operation is between 0.2 l/min and 1 l/min, the throughput of the purging operation is 1 l/min, an inert gas, in particular with a degree of purity of 6.0, is filtered through a gas cleaning cartridge before entering into the process chamber, the duration of the soldering is at least 10 hours, in particular at least 48 hours, the solder ( 10 ) is solidified in polycrystalline form (CC), in particular in CC components.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained with reference to the following drawings. In the drawings:
FIG. 1 shows two cross-sectional views of a component during and after treatment with the solder according to the invention,
FIG. 2 shows a perspective view of a turbine blade or vane,
FIG. 3 shows a perspective view of a combustion chamber,
FIG. 4 shows a gas turbine, and
FIG. 5 shows a list of superalloys.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a component 1 which is treated with a solder 10 consisting of a solder alloy according to the invention.
The component 1 comprises a substrate 4 which, particularly in the case of components for high temperature applications, in particular in the case of turbine blades or vanes 120 , 130 ( FIG. 2 ) or combustion chamber elements 155 ( FIG. 3 ) for steam or gas turbines 100 ( FIG. 4 ), consists of a nickel-base or cobalt-base superalloy ( FIG. 5 ).
The solder 10 can preferably be used for all the alloys according to FIG. 5 .
These may preferably be the known materials PWA 1483, PWA 1484 or Rene N5.
The solder 10 is also used in blades or vanes for aircraft.
A crack 7 or depression 7 which is to be filled by soldering is present in the substrate 4 . The cracks 7 or depressions 7 preferably have a width of about 200 μm and may have a depth of up to 5 mm.
In this case, the solder 10 consisting of a solder alloy is applied into or close to the depression 7 , and the solder 10 is melted by heat treatment (+T) below a melting temperature of the substrate 4 and completely fills the depression 7 .
The solder alloy 10 is based on nickel and therefore the largest proportion of said alloy is preferably taken up by nickel (Ni).
A binary system of Ni—Ge or Ni—Ga is used with preference.
The gallium (Ga) content is preferably at least 0.1% by weight. The germanium content is likewise preferably at least 0.1% by weight. Even these small proportions influence the soldering behavior of nickel or a nickel alloy.
In addition to a remainder of nickel and gallium and/or germanium, the further constituents of chromium (Cr), cobalt (Co), aluminum (Al) and titanium (Ti), tungsten (W), molybdenum (Mo) or tantalum (Ta) may preferably be present which, if used, are each preferably used in a proportion of at least 0.1% by weight.
The chromium content is preferably in a range from 2% by weight-10% by weight, in particular in a range from 3% by weight-9% by weight, with particularly preferred exemplary embodiments having a chromium content of 4% by weight or 8% by weight, and therefore preferred chromium values are also in a range from 3% by weight to 5% by weight or 7% by weight to 9% by weight, preferably 8% by weight.
The chromium content is also preferably 4% by weight.
The aluminum content is preferably in a range from 1% by weight-5% by weight, particularly preferably in a range from 2% by weight-4% by weight. A particularly good exemplary embodiment has a solder alloy with an aluminum content of 3% by weight.
The tungsten content is preferably in a range from 2% by weight-6% by weight, particularly preferably in a range from 3% by weight-5% by weight. Particularly good results have been achieved with a tungsten content of 4% by weight.
The cobalt content is in a range from 2% by weight-10% by weight, particularly preferably in a range from 3% by weight-9% by weight. Particularly preferred exemplary embodiments have a cobalt content of 4% by weight or 8% by weight, and therefore particularly preferred cobalt contents are 3% by weight to 5% by weight or 7% by weight to 9% by weight, particularly 8% by weight. The cobalt content is also preferably 4% by weight.
The gallium or germanium content is preferably at least 3% by weight, particularly preferably at least 6% by weight. The germanium or gallium content may preferably be limited to a maximum value of 18% by weight. The maximum gallium or germanium content is likewise preferably 13% by weight and very particularly preferably 8% by weight.
The gallium (Ga) content in a nickel-base superalloy as the solder alloy is preferably between 28% by weight and 35% by weight.
The germanium content is preferably between 18% by weight and 28% by weight, in particular 20% by weight, 23% by weight, 26% by weight or 27% by weight, particularly in the case of binary systems, i.e. NiGe20, NiGe23 or NiGe26, in particular for solidification in single crystal form.
The above list of the solder constituents of nickel, chromium, cobalt, tungsten, aluminum, gallium or germanium is preferably conclusive.
Preference is given to using either only gallium or germanium.
The text which follows lists the conclusive composition of advantageously used alloys, where the alloy comprises either only germanium or only gallium or else germanium and gallium (G=gallium and/or germanium, i.e. only Ga or only Ge or Ga and Ge):
Ni—Cr-G
Ni—Co-G
Ni—W-G
Ni—Al-G
Ni—Cr—Co-G
Ni—Cr—W-G
Ni—Cr—Al-G
Ni—Co—W-G
Ni—Co—Al-G
Ni—W—Al-G
Ni—Cr—Co—W-G
Ni—Cr—Co—Al-G
Ni—Cr—W—Al-G
Ni—Co—W—Al-G
Ni—Cr—Co—W—Al-G.
The solder 10 preferably does not contain any boron. Likewise, the solder 10 preferably does not contain any zirconium. The addition of rhenium may likewise preferably be omitted. Likewise, preference is given to not using any hafnium.
The addition or the presence of silicon and/or carbon is preferably avoided since they form brittle phases in the solder.
The addition or the presence of iron and/or manganese is likewise preferably avoided since these elements form low-melting phases or non-oxidizing phases.
The solder 10 may be joined to the substrate 4 of the component 1 , 120 , 130 , 155 in an isothermal process or a temperature gradient process. A gradient process is preferably suitable when the substrate 4 has a directional structure, for example an SX or DS structure, such that the solder 10 then also has a directional structure. However, a directionally solidified structure in the solder may also be provided in an isothermal process.
Equally, the component 1 does not need to have a directionally solidified structure (but rather a CC structure).
The solders in CC substrates of components may likewise be soldered and solidified in a CC structure, the solders then being solidified in polycrystalline form (CC).
The following solders are of particular interest especially for the polycrystalline solidification of the solders:
NiGe
NiGeW4Al3
NiGeCo8W4
NiGeCr8W4
NiGeCr8Co8W4Al3
NiGeCr8Co8
NiGeCo8Al3
NiGeCr8Al3
NiGeCr4Co4W2Al1.5.
In this case, the germanium content is from 20% by weight-30% by weight, in particular 26% by weight or 27% by weight.
During the melting (isothermal process or gradient process), use is preferably made of an inert gas, in particular argon, which reduces the vaporization of chromium from the substrate 4 at the high temperatures, or a reducing gas (argon/hydrogen) is used.
The solder 10 may also be applied to a large area of a surface of a component 1 , 120 , 130 , 155 in order to thicken the substrate 4 , in particular in the case of hollow components. The solder 10 is preferably used to fill cracks 7 or depressions 7 .
When a solder 10 is soldered in vacuo, which is often carried out when the solder 10 or the component 1 , 120 , 130 , 155 oxidizes, the use of inert gases (Ar, He, Ar/He, H 2 . . . ) and/or the use of a vacuum preferably results in the problem of constituents of the component 1 , 120 , 130 , 155 or of the solder 10 vaporizing at an excessively low process pressure.
At an excessively high oxygen partial pressure p O2 , the solder 10 or the component 1 , 120 , 130 , 155 oxidizes.
The process according to the invention therefore also preferably proposes carrying out the soldering process in vacuo in a process chamber, preferably in a furnace at an oxygen partial pressure p O2 of at most 10 −6 mbar (10 −4 Pa).
The oxygen partial pressure p O2 is preferably at least 10 −7 mbar (10 −5 Pa). The overall process pressure is preferably at most 100 mbar (10 000 Pa), in particular at most 10 mbar (1000 Pa). The overall process pressure is preferably at least 0.1 mbar (10 Pa). Particularly good soldered joins have been achieved at a pressure of 1 mbar (100 Pa).
These pressure values are achieved, in particular, due to the fact that the process chamber has a vacuum in its interior, is preferably permanently pumped out and, before the soldering, is preferably purged with a pure inert gas, preferably argon (Ar) (Ar 5.0, preferably Ar 6.0). This is preferably carried out for at least 10 hours, in particular for 48 hours with a throughflow rate of preferably between 0.2 l/min and 1 l/min.
In this case, preference is given to using argon 6.0 (this means an oxygen content of 5×10 −7 in the process gas) which, however, is preferably filtered through a gas cleaning cartridge, such that the oxygen and water content is reduced by a factor of 100 so as to achieve an oxygen content of 5×10 −9 in the process gas introduced into the process chamber.
Argon is likewise preferably present within the pressure values described above during the soldering operation.
The temperature during the soldering process is at least 1140° C., in particular at least 1160° C. Further advantageous soldering temperatures are 1160° C., 1180° C., 1200° C., 1230° C. and 1260° C. The maximum temperature is preferably 1280° C., in particular at most 1260° C.
The duration of the soldering treatment is preferably at least 10 hours, in particular 48 hours.
FIG. 2 shows a perspective view of a rotor blade 120 or guide vane 130 of a turbomachine, which extends along a longitudinal axis 121 .
The turbomachine may be a gas turbine of an aircraft or of a power plant for generating electricity, a steam turbine or a compressor.
The blade or vane 120 , 130 has, in succession along the longitudinal axis 121 , a securing region 400 , an adjoining blade or vane platform 403 and a main blade or vane part 406 and a blade or vane tip 415 .
As a guide vane 130 , the vane 130 may have a further platform (not shown) at its vane tip 415 .
A blade or vane root 183 , which is used to secure the rotor blades 120 , 130 to a shaft or a disk (not shown), is formed in the securing region 400 .
The blade or vane root 183 is designed, for example, in hammerhead form. Other configurations, such as a fir-tree or dovetail root, are possible.
The blade or vane 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the main blade or vane part 406 .
In the case of conventional blades or vanes 120 , 130 , by way of example solid metallic materials, in particular superalloys, in particular the superalloys according to FIG. 5 , are used in all regions 400 , 403 , 406 of the blade or vane 120 , 130 .
Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloy.
The blade or vane 120 , 130 may in this case be produced by a casting process, by means of directional solidification, by a forging process, by a milling process or combinations thereof.
Workpieces with a single-crystal structure or structures are used as components for machines which, in operation, are exposed to high mechanical, thermal and/or chemical stresses.
Single-crystal workpieces of this type are produced, for example, by directional solidification from the melt. This involves casting processes in which the liquid metallic alloy solidifies to form the single-crystal structure, i.e. the single-crystal workpiece, or solidifies directionally.
In this case, dendritic crystals are oriented along the direction of heat flow and form either a columnar crystalline grain structure (i.e. grains which run over the entire length of the workpiece and are referred to here, in accordance with the language customarily used, as directionally solidified) or a single-crystal structure, i.e. the entire workpiece consists of one single crystal. In these processes, a transition to globular (polycrystalline) solidification needs to be avoided, since non-directional growth inevitably forms transverse and longitudinal grain boundaries, which negate the favorable properties of the directionally solidified or single-crystal component.
Where the text refers in general terms to directionally solidified microstructures, this is to be understood as meaning both single crystals, which do not have any grain boundaries or at most have small-angle grain boundaries, and columnar crystal structures, which do have grain boundaries running in the longitudinal direction but do not have any transverse grain boundaries. This second form of crystalline structures is also described as directionally solidified microstructures (directionally solidified structures).
Processes of this type are known from U.S. Pat. No. 6,024,792 and EP 0 892 090 A1; these documents form part of the disclosure with regard to the solidification process.
The blades or vanes 120 , 130 may likewise have coatings protecting against corrosion or oxidation e.g. (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element, or hafnium (Hf)). Alloys of this type are known from EP0 486 489 B1, EP0 786 017 B1, EP0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy.
The density is preferably 95% of the theoretical density.
A protective aluminum oxide layer (TGO=thermally grown oxide layer) is formed on the MCrAlX layer (as an intermediate layer or as the outermost layer).
The layer preferably has a composition Co-30Ni-28Cr-8Al-0.6Y-0.7Si or Co-28Ni-24Cr-10Al-0.6Y. In addition to these cobalt-base protective coatings, it is also preferable to use nickel-base protective layers, such as Ni-10Cr-12Al-0.6Y-3Re or Ni-12Co-21Cr-11Al-0.4Y-2Re or Ni-25Co-17Cr-10A1-0.4Y-1.5Re.
It is also possible for a thermal barrier coating, which is preferably the outermost layer and consists for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, to be present on the MCrAlX.
The thermal barrier coating covers the entire MCrAlX layer. Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
Other coating processes are possible, for example atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may include grains that are porous or have micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks. The thermal barrier coating is therefore preferably more porous than the MCrAlX layer.
Refurbishment means that after they have been used, protective layers may have to be removed from components 120 , 130 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the component 120 , 130 are also repaired. This is followed by recoating of the component 120 , 130 , after which the component 120 , 130 can be reused.
The blade or vane 120 , 130 may be hollow or solid in form. If the blade or vane 120 , 130 is to be cooled, it is hollow and may also have film-cooling holes 418 (indicated by dashed lines).
FIG. 3 shows a combustion chamber 110 of a gas turbine. The combustion chamber 110 is configured, for example, as what is known as an annular combustion chamber, in which a multiplicity of burners 107 , which generate flames 156 , arranged circumferentially around the axis of rotation 102 open out into a common combustion chamber space 154 . For this purpose, the combustion chamber 110 overall is of annular configuration positioned around the axis of rotation 102 .
To achieve a relatively high efficiency, the combustion chamber 110 is designed for a relatively high temperature of the working medium M of approximately 1000° C. to 1600° C. To allow a relatively long service life even with these operating parameters, which are unfavorable for the materials, the combustion chamber wall 153 is provided, on its side which faces the working medium M, with an inner lining formed from heat shield elements 155 .
On the working medium side, each heat shield element 155 made from an alloy is equipped with a particularly heat-resistant protective layer (MCrAlX layer and/or ceramic coating) or is made from material that is able to withstand high temperatures (solid ceramic bricks).
These protective layers may be similar to the turbine blades or vanes, i.e. for example MCrAlX: M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one rare earth element or hafnium (Hf). Alloys of this type are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition of the alloy.
It is also possible for a, for example, ceramic thermal barrier coating to be present on the MCrAlX, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
Other coating processes are possible, e.g. atmospheric plasma spraying (APS), LPPS, VPS or CVD. The thermal barrier coating may include grains that are porous or have micro-cracks or macro-cracks, in order to improve the resistance to thermal shocks.
Refurbishment means that after they have been used, protective layers may have to be removed from heat shield elements 155 (e.g. by sand-blasting). Then, the corrosion and/or oxidation layers and products are removed. If appropriate, cracks in the heat shield element 155 are also repaired. This is followed by recoating of the heat shield elements 155 , after which the heat shield elements 155 can be reused.
Moreover, a cooling system may be provided for the heat shield elements 155 and/or their holding elements, on account of the high temperatures in the interior of the combustion chamber 110 . The heat shield elements 155 are then, for example, hollow and may also have cooling holes (not shown) opening out into the combustion chamber space 154 .
FIG. 4 shows, by way of example, a partial longitudinal section through a gas turbine 100 .
In the interior, the gas turbine 100 has a rotor 103 with a shaft 101 which is mounted such that it can rotate about an axis of rotation 102 and is also referred to as the turbine rotor.
An intake housing 104 , a compressor 105 , a, for example, toroidal combustion chamber 110 , in particular an annular combustion chamber, with a plurality of coaxially arranged burners 107 , a turbine 108 and the exhaust-gas housing 109 follow one another along the rotor 103 .
The annular combustion chamber 110 is in communication with a, for example, annular hot-gas passage 111 , where, by way of example, four successive turbine stages 112 form the turbine 108 .
Each turbine stage 112 is formed, for example, from two blade or vane rings. As seen in the direction of flow of a working medium 113 , in the hot-gas passage 111 a row of guide vanes 115 is followed by a row 125 formed from rotor blades 120 .
The guide vanes 130 are secured to an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are fitted to the rotor 103 for example by means of a turbine disk 133 .
A generator (not shown) is coupled to the rotor 103 .
While the gas turbine 100 is operating, the compressor 105 sucks in air 135 through the intake housing 104 and compresses it. The compressed air provided at the turbine-side end of the compressor 105 is passed to the burners 107 , where it is mixed with a fuel. The mix is then burnt in the combustion chamber 110 , forming the working medium 113 . From there, the working medium 113 flows along the hot-gas passage 111 past the guide vanes 130 and the rotor blades 120 . The working medium 113 is expanded at the rotor blades 120 , transferring its momentum, so that the rotor blades 120 drive the rotor 103 and the latter in turn drives the generator coupled to it.
While the gas turbine 100 is operating, the components which are exposed to the hot working medium 113 are subject to thermal stresses. The guide vanes 130 and rotor blades 120 of the first turbine stage 112 , as seen in the direction of flow of the working medium 113 , together with the heat shield elements which line the annular combustion chamber 110 , are subject to the highest thermal stresses.
To be able to withstand the temperatures which prevail there, they may be cooled by means of a coolant.
Substrates of the components may likewise have a directional structure, i.e. they are in single-crystal form (SX structure) or have only longitudinally oriented grains (DS structure).
By way of example, iron-base, nickel-base or cobalt-base superalloys are used as material for the components, in particular for the turbine blade or vane 120 , 130 and components of the combustion chamber 110 .
Superalloys of this type are known, for example, from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949; these documents form part of the disclosure with regard to the chemical composition of the alloys.
The blades or vanes 120 , 130 may also have coatings which protect against corrosion (MCrAlX; M is at least one element selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon, scandium (Sc) and/or at least one rare earth element or hafnium). Alloys of this type are known from EP0 486 489 B1, EP0 786 017 B1, EP0 412 397 B1 or EP 1 306 454 A1, which are intended to form part of the present disclosure with regard to the chemical composition.
A thermal barrier coating, consisting for example of ZrO 2 , Y 2 O 3 —ZrO 2 , i.e. unstabilized, partially stabilized or fully stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide, may also be present on the MCrAlX.
Columnar grains are produced in the thermal barrier coating by suitable coating processes, such as for example electron beam physical vapor deposition (EB-PVD).
The guide vane 130 has a guide vane root (not shown here), which faces the inner housing 138 of the turbine 108 , and a guide vane head which is at the opposite end from the guide vane root. The guide vane head faces the rotor 103 and is fixed to a securing ring 140 of the stator 143 . | Many known solder alloys according to prior art utilize silicon or boron as melting point reducers, which, however, form brittle phases that have an undesirable effect on the thermo-mechanical properties. The invention relates to a solder ally that comprises gallium and/or germanium, preferably forms the Y′ phase and has improved mechanical properties. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a method for preparing bamboo to produce a bamboo pulp suitable for producing high strength paper products. More particularly, this invention relates to a method of preparing bamboo for digestion at an elevated temperature and pressure by shredding, washing and wet depithing.
DESCRIPTION OF THE INVENTION
Bamboo is present in the world in many varieties. One prevalent variety, and one which contains relatively long fibers, is Bambusa Vulgaris. A typical bamboo of this variety contains about 10 percent pith and about 8 percent nodes and silica. The nodes are the barriers that divide the bamboo into linear segments. The true fiber content is about 60 percent with vessel segments comprising about 22 percent. Vessel segments are the conduits or tubes that transport the liquid nutrients. The paper making value of vessel segments is low. The true fiber content is the high quality fiber portion that forms the pulp after digestion.
The chemical composition of Bambusa Vulgaris does not differ that must from typical pine wood fiber sources. The following Table 1 provides typical analytical data for Bambusa Vulgaris and for three varieties of pine wood.
TABLE 1______________________________________ Pine Wood FibersComponent B. Vulgaris Saligna Elliotti Augustifol______________________________________Cellulose 49.2 54.6 55.5 58.3Lignin 14.5 25.5 26.6 28.5Pentosans 22.3 16.4 7.1 6.1Solubles:NaOH 1% 33.4 14.8 16.9 10.6Hot Water 15.0 1.6 3.8 2.5Alcohol/Benzene 5.2 1.4 6.7 0.9Ash 1.8 0.3 0.3 0.3______________________________________
In addition, the length of usable fibers of Bambusa Vulgaris is similar to that of the typical pine sources. However, one signifricant difference is the higher wax and phenolic content of bomboos which necessitates different processing and digestion than is suitable for pine woods. This wax content protects the bamboo from moisture and insects as it grows and must be removed to produce a good pulp.
A tpyical method for preparing bamboo for digestion is to chip the bamboo. This is a techinque used extensively for producing pulps from pine woods. A chipper is a piece of machiner with a series of knives which cut chips of the bamboo from the larger stalks. The chips are of a size of about 0.32 cm. thick, about 1.9 cm. in length and in width. In contrast to a chipper, a shredder produces elongated fragments. While a shreadded would be useful for wood, it is very useful for bamboo. Bamboo is essentially a series of hollow segments having a wall thickness of about 1 to 3 centimeters. Shredded bamboo consists of elongated fragments of from 10 to 25 centimeters or more in length. The result is that there are most longer fibers present after shredding than after shipping. Chipping cuts many fibers and thus results in a greater number of shorter fibers in the final pulp. Shredding does not cut the fibers. The fibers are not damaged at the first stage of processing. In addition, shredding produces a fiber that can be further processed prior to digestion. A chipped bamboo in many prior art processes is then flowed directly to impregnation and/or digestion after chipping. However, in the prior process of the present inventor, the chipped bamboo was then shredded and depithed. In contrast in the new process, the bamboo is solely shredded and then is passed to a washer such as the Peadco Washer described in U.S. Pat. No. 3,992,745 and then wet depithed using a depither such as the Peadco Depither described in U.S. Pat. No. 3,688,345. The result is a long input fiber with less fiber damage to digestion which has a substantial amount of the non-fibrous material removed and which can be digested at a faster rate. Digestion proceeds at a faster rate since the depithed fibers are quickly impregnated with the black liquor and digestion chemical solutions.
This particular pre-digestion processing for bamboo is preferably used in combination with a digestion process which consists of a sequence of treatment with black liquor or digestion chemicals at a super atmospheric pressure for a first period of time, the addition of further digestion chemicals followed by a rapid reduction in pressure of at least about 0.5 kg/cm 2 , and a treatment at this lower, but super-atmospheric, pressure for a second period of time. This sequence of digestion chemical addition followed by a rapid pressure reduction can be repeated a number of times. Each rapid pressure reduction opens the fiber bundles by the conversion of included water to steam and also causes the concentration of the added digestion chemicals on the fibers. When this digestion sequence is used in combination with the above described pre-processing sequence a pulp is obtained which is very similar to that of a wood long fiber source.
SUMMARY OF THE INVENTION
In brief summary, this invention relates to the preparation of bamboo for digestion by shredding the bamboo, washing the shredded bamboo to remove solubles, dirt and other occluded material, and wet depithing the washed and shredded bamboo. The bamboo is then digested at an elevated temperature and pressure using black liquor and optionally digestion chemicals in the first digestion step, and digestion chemicals in subsequent steps. Between each digestion step there is a rpaid reduction of the pressure on the bamboo fibers. Also, each addition of digestion chemicals in the subsequent digestion steps is just prior to the rapid pressure reduction. This provides for better fiber opening and a concentration of the added chemicals on the newly exposed fiber surfaces.
BRIEF DESCRIPTION OF THE DRAWING
The FIG. 1 is a schematic of the preferred method of practicing the present process.
DETAILED DESCRIPTION OF THE INVENTION
The quality of bamboo pulp is directly related to the extent of the removal of parenchyma cells and nodes. The parenchyma cells which are spongy and have a high liquid absorption potential. They keep the plant liquid nutrients "in storage"0 until they are consumed by the plant. The nodes are the segments which divide the bamboo stalk into sections. Water and various nutrients pass up the bamboo stalk. The nodes permit the passage of water and these nutrients, but removes silica, various minerals and other inorganics. It is the present objective to remove the parenchyma cells and the nodes at an early part of the processing. This then leaves primarily the fine structure of the bamboo fiber for processing. This is very similar to that of soft woods with one primary wall and three distinct secondary wall layers.
Most processes for making a bamboo pulp are batch processes. Batch processes and continuous processes give about the same results if the bamboo is not properly prepared. Most efforst thusfar to improve bamboo pulp has centered on the digestion stage. Batch processes have been converted to continuous processes. Processing times, temperatures and pressures have been changed again and again. The digestion chemicals and their ratios have been changed. However, there are not signficant advances unless the fiber is properly prepared prior to digestion. The present process will now be more particularly described with reference to the Figure.
In accordance with the Figure, the bamboo fiber should first be shredded. Bamboo is fed directly to a shredder such as the horizontal, multihammer shredder. This device consists of a heavy rotor, hammers, bed plate and a grill or bar screen. Bamboo of a smaller diameter, such as that less than 1 inch diamber, can first be fed to a cutter which will produce a product of maximum 2 inches long, the cuttings can be opened by a smaller shredder. In this way a smaller and less costly shredding device can be used.
The shredded bamboo which is in long segements of about 10 to 25 centimeters or more is then fed to a washer to remove solubles as well as rock, sand and other foreign material. Although many types of washers can be used it is preferred to use a washer which continuously submerges and works the shredded bamboo. A very useful washer is that described in U.S. Pat. No. 3,992,745, an improvement of which is described in U.S. Pat. No. 4,635,322. This is a U-shaped washer with the fiber input into one leg of the U and exiting the other leg of the U. Each leg of the washer contains rollers with tines which continuously submerge and work the fibers. At the loop of the U there is a deepened area where rock, dirt and other materials can be removed from the washer. The fibers are drained at the exit leg of the washer and fall from the washer into a pin feeder which feeds the shredded bamboo into the wet depither. Fresh water is continuously added to the washer to make-up for water losses.
The wet depither is preferably of a type as described in U.S. Pat. No. 3,688,345, an improvement of which is described in U.S. Pat. No. 4,641,792. This depither consists of a central rotor surrounded by a perforated basket. The rotor contains a series of knives which are arranged in a pattern to produce a downward spiral motion to the input fiber. The ends of the knives work the fibers against the perforated wall of the basket. Simultaneously water is injected into the depither. The combination of the action of the knives and the centrifugal force of water and air being propelled toward the basket by the rotating rotor reduces the size of the fiber bundles and forces the parenchyma, nodes, sand and short fibers through the basket wall. The water also removes various soluble components from the fibers. A fiber about 3 to 5 centimeters in length exits the depither. This existing fiber has a water content of about 78 percent to 85 percent. This fiber is then ready for input into a digester, and preferably a continuous digester. Water is added to the wet depither to maintain a continuous flow of water through the basket and to maintain the fiber at a water content of about 10 percent to 14 percent while the fiber is being worked in the depither.
A useful digestion process is one which contains multiple blow steps. By multiple blow is meant a process whereby the fiber undergoes a number of treatment steps at an elevated temperature and pressure. In between each step there is a rapid pressure reduction to a lower super atmospheric pressure. The rapid pressure reduction serves to open the fibers. Immediately prior to each rapid pressure reduction digestion chemicals are added if any are to be added to the process. The digestion chemicals that can be used are selected from the group consisting of sodium hydroxide, sodium sulfite, sodium bisulfite, sodium carbonate, oxygen, a bleach and mixtures thereof. The useful elevated operating temperature for the processing is in the range of bout 150° C. (centigrade) to 200° C. and preferably about 170° C. to 180° C. The pressure is the pressure of water (steam) at this temperature. In the rapid pressure reductions the pressure is reduced at least about 0.5 kg/cm 2 . Although there is usually a black liquor impregnation and digestion step at the elevated temperature and pressure, an addition of digestion chemicals, a rapid pressure reduction, and a digestion with the added digestion chemicals followed by a blowdown to atmospheric pressure, additional steps of digestion chemical addition and rapid pressure reduction followed by digestion can be incorporated prior to the blowdown step. Further, the fiber can undergo a refining step prior to one or more of the rapid depressurization steps and prior to the blowdown to atmospheric pressure. Refining aids in breaking down the fiber bundles. The resulting pulp is then prepared like any other pulp for papermaking. These inlcude steps of washing, screening and centrifuging and optionally bleaching. The steps that would be used would depend on the paper products to be produced.
The following examples further describe the present invention.
EXAMPLE 1
This example describes the processing of a bamboo according to the present preparation method to produce bamboo pulp.
A long stalk Bamboo Vulgais (about 10 meters) was shredded using a horizontal multi-hammer shredder. The bamboo was shredded at the rate of 8 tons per hour. The shredded bamboo was flowed to a pin feeder and into a Peadco Washer. The residence time in the Peadco Washer is about 1 minute. From the exit of the Peadco Washer the washed bamboo fiber falls into the Peadco Wet Depither. The fiber exits the Peadco Wet Depither and is fed by means of a screw feeder to a tubular digester. The tubular digester has an inner diamger of 45 inches and a length of 30 feet. The fibers are moved through the tubular digester by a screw rotating at the rate of 1 RPM.
Along with the fiber black liquor and steam at 180° C. are added to the tubular digester. The black liquor is added to give a water/fiber ratio of 2.15:1. The black liquor has the following composition:
______________________________________sodium hydroxide 0.2%sodium carbonates 6-7%lignin 5-8%silica 1.5%______________________________________
After about 12.5 minutes in the first digester the fiber is removed and a 10 percent by weight sodium hydroxide solution is added to give a sodium hydroxide/fiber ratio of 12.5%. This fiber is then defibered in a refiner and the pressure rapidly reduced by 1.0 kg/cm 2 . Subsequently, the fiber flows into a second tubular digester of the same size as the first digester. The residence time of the fiber in this digester is 22.5 minutes whereafter the fiber is refined and the pressure reduced to atmospheric pressure. This fiber is then washed and centrifuged. The fiber yield is 55% and the K number 29/30. This pulp is suitable for making a kraft paper.
EXAMPLE 2
The procedure of Example 1 is repeated except that the ratio of sodium hydroxide to fiber is 15%. The yield is 50% and the K MnO 4 is 16/18. The G.E. Brightness is 40. This pulp is bleached using a three stage sequence. The final G.E. brightness is 84/86. This pulp is used to make writing paper.
EXAMPLE 3
This example describes the processing of a bamboo by a conventional chipping method to produce a bamboo pulp.
A long stalk bamboo was chipped into pieces of about 1.9 cm in length and width and about 0.32 cm thick. these chips were placed in a vertical digester and heated at 170° C. for 4 hours and 15 minutes. The water to fiber ratio was 4 to 1 and the sodium hydroxide to fiber percen5tage was 21%. After digestion, the fibers are blown down to atmospheric pressure. The properties of this pulp are set out in Table II in Example 4.
EXAMPLE 4
This example sets out a comparison of the properties of the bamboo pulp of Example 1 and Example 3 and a further comparison with the properties of a conventional wood pulp. The following Table II gives the comparison of these properties.
TABLE II______________________________________ WOODPROPERTY EXAMPLE 1 EXAMPLE 3 PULP______________________________________Initial Freenessml. C.S.F. 720 700 730Properties Freenessml. C.S.F. 450 450 450Tear Factor = R 221 150 126Burst Factor 62 48 82Tensile km. = T 8.1 7.0 9.6Index TXR 1790 1050 1209______________________________________
The wood pulp is a conventional long fiber wood pulp from a soft wood source. This Table shows the bamboo pulp which had undergone the new processing according to this application has superior properties to a bamboo that had been chipped and is similar in many respect to a wood pulp. | Bamboo can be formed into a suitable pulp if prior to digestion it undergoes a process of shredding, washing and wet depithing. The fibers are then chemically digested preferably by a process which uses rapid pressure drops to open the fibers using the energy contained in the wet superheated fibers. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a coil spring which has a predetermined free length and also has a desirable elasticity.
2. Prior Art
Conventionally, as shown in FIG. 4, coil springs are manufactured using a coiling pin 1, a pitch tool 2, etc. incorporated in a coil fabricating apparatus.
A wire material W, which is formed into a coil spring, is passed through a wire guide 3 and fed out by being sandwiched between a pair of feed rollers 4 and 5. The wire material W is further passed through wire guides 6 and 6a and is caused to contact the coiling pin 1 so that the wire material W is shifted onto a core piece 7.
The wire material W is thus formed into a helical shape of a prescribed pitch by the pitch tool 2. The helical shaped wire material W is then cut by a cutting tool 8 into a coil spring.
Generally, coil springs are required to have a predetermined free length and a desirable performance; and it is particularly necessary that a predetermined free length, which is the total length of a coil spring, is constant for each and every coil spring manufactured.
Conventionally, a single coil spring is manufactured by feeding a wire material which has a length that is necessary to fabricate a single coil spring, and then the free length of the completed coil spring is measured by a contact or non-contact type sensor. The free length is compared with a predetermined set-length, and coil springs which are longer or shorter than the reference length are discarded as defective products. If the defective products exceed a certain number, a motor which adjusts the pitch tool 2 is actuated so as to finely adjust the pitch, thus insuring that subsequent coil springs will have the predetermined free length.
Usually, the free length of a coil spring is affected by the characteristics of the wire material itself and by the variation in the wire habit, tensile force, etc. of the wire material. Thus, some coil fabricating apparatuses take such factors into consideration in order to manufacture coils which have a predetermined free length.
However, in these systems, since the free length of the finished coil spring is checked after the completion of wire fabrication to find satisfactory and defective springs, there still are problems. In particular, the coil springs are measured, after being made, for its free length, but obviously the finished springs cannot be modified. In addition, the wire material includes factors (such as wire habit, etc.) which can be altered during the process of wire pulling which is one of the steps of coil spring manufacturing. Such factors can greatly affect the resulted springs. Accordingly, even if the wire material has a predetermined length, the free length of the coil spring can vary and does not sustain consistency.
Furthermore, in the systems which take the wire material characteristics and the variations in wire habit, tensile force, etc. into account, such elements are brought into the tool set-up process or into the reference values input process, which are performed in the initial stage of coil manufacturing. If the material factors change during the manufacturing process, since the initial set-ups as described above cannot be altered in response to these changes, the number of defective products tends to be high when the systems where the free length is measured after the completion of coiling is utilized. In particular, when an attempt is made to produce coil springs with a highly precise free length, the rate of satisfactory products tends to drop.
SUMMARY OF THE INVENTION
The object of the present invention is to solve the prior art problems described above. In particular, the present invention provides a method which makes it possible to manufacture coil springs with a high rate of satisfactory production and with the precision of the free length of the coil springs kept at a high level.
The method of manufacturing coil springs provided by the present invention is characterized in that coil springs are manufactured with priority given to the free length of the coil springs. More specifically, when the coil spring in the process of manufacturing reaches a length which is equal to a predetermined entire length for the coil spring minus the length of the end coiling section, this length is detected by a sensor. A pitch tool is operated on the basis of this detection signal so as to start the formation of the end-coiling section. When the formation of the end-coiling section is completed, the coil spring is cut by a cutting tool, and at the same time, the length of the wire material used for the finished coil spring is measured. Then, a check is made to see whether or not this length is within a predetermined range.
Thus, in each of the coil springs manufactured by the method of the present invention, the length of the initial and main sections of the spring will always be the same for every spring, and the end-coiling section of a predetermined length is added thereto. The lengths of the initial-coiling section and the end-coiling section are very short and more or less constant, and such lengths do not affect to the overall free length of the spring. Accordingly, the precision of the free length of the coil spring manufactured by the method of the present invention can be extremely high. Furthermore, since the length of the wire material which is turned into a coil spring is kept within a fixed range, a desired spring performance is secured for every spring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram which illustrates the relationship (in model form) of the main parts of an apparatus which uses the coil spring manufacturing method of the present invention;
FIG. 2 is an enlarged top view which shows the main section of the a of FIG. 1;
FIG. 3 is a flow chart showing the steps of the manufacturing method of the present invention; and
FIG. 4 is a schematic side view of a prior art apparatus for manufacturing coil springs.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described with reference to the accompanying drawings.
FIGS. 1 and 2 illustrate (in schematic form) one example of an apparatus which uses the method of the present invention. This coil fabricating apparatus, like the prior art apparatus shown in FIG. 4, is equipped with a coiling pin 1 which forms the wire material W into a bent shape (or a coil spring) and determines the external diameter of the coil spring. A pitch tool 2 which determines the pitch of a coil spring C, a pair of wire material feed rollers 4 and 5, a cutting tool 8, etc. are also incorporated in the apparatus.
The coil fabricating apparatus of the present invention further includes a control unit 10 (as a motion controller) which includes a CPU (microcomputer) that controls the pitch tool 2, the feed rollers 4 and 5, etc. as shown in FIG. 1.
Furthermore, as shown in FIG. 2, the apparatus further includes detectors 11 which detect the length of the coil spring C being manufactured. The detectors detect the length that is equal to a predetermined free length of the coil spring minus the length of the end-coiling section. A laser sensor or an optical sensor is used as the detector, and a proximity switch, etc. could also be used.
The pitch tool 2 is adjusted by a first servo motor 13 via an appropriate transmission mechanism, e.g., a cam mechanism 12, as shown in FIG. 1. The first servo motor 13 is connected to the control unit 10 via a first drive unit 14, so that the pitch tool 2 is actuated by signals from the control unit 10. A rotary encoder 15 is mounted to the first servo motor 13. The encoder 15 inputs pulse signals, which correspond to the amount of movement of the pitch tool 2, into the control unit 10.
The feed rollers 4 and 5 feed the wire material W to the coiling pin 1. It is designed so as to prevent slippage between the wire material W and the rollers 4 and 5. The rollers 4 and 5 are commonly driven by a second servo motor 16 via gears, etc. The second servo motor 16 is connected to the control unit 10 via a second drive unit 17. The reference numeral 18 is a rotary encoder which is also mounted to the second servo motor 16.
Thus, the rollers 4 and 5 are actuated by command signals from the control unit 10, and the rotation of the rollers, in other words, the amount of feed of the wire material W, is inputted into the control unit 10.
A piston-cylinder 19 which acts as a driving means for a reciprocating motion of the cutting tool 8 is also connected to the control unit 10. The reference numeral 20 refers to a selecting device which selects satisfactory coil springs in accordance with commands from the control unit 10.
FIG. 3 is a flow chart of the coil spring manufacturing method of the present invention.
The wire material W is first fed by the feed rollers 4 and 5 so that the initial-coiling section and the main-coiling section (that is an effective coil part), which follows the initial-coiling section, are formed. When it is sensed, based upon the length of the wire material fed out, that the forward end of the coiled spring approaches a position where the coil spring is detected by the detector 11, the feeding speed of the wire material is slowed down; then, when the coil spring is detected by the detector 11, the resulting detection signal is inputted into the control unit 10, and the first servo motor 13 is actuated via the first drive unit 14 so that the pitch tool 2 is moved (upward in FIG. 2), thus starting the formation of the end-coiling section.
The position of the detection performed by the detectors 11 is set so as to be equal to the predetermined free length of the coil spring minus the length of the end-coiling section. Accordingly, the position of the detector 11 is always constant or remains unchanged; as a result, the free length of the manufactured springs is constant. The end-coiling section is formed so as to have a preset length, and when the formation of the end-coiling section is completed, the cutting tool 8 is actuated by the driving action of the cylinder 19 so that the wire material is cut at the position of the core piece 7. One cycle of the wire manufacturing process is thus completed.
When one cycle of the coil spring manufacturing is thus completed, the amount of wire material fed out during the one cycle span, i.e., the length of the wire material used in the coil spring, is calculated based upon the angle of rotation of the second servo motor 16 that drives the feed rollers 4 and 5. The value thus obtained is inputted into the control unit 10 via the rotary encoder 18. In the control unit, this value is compared with a preset reference wire length. If the difference between the two lengths is permissible, the finished coil spring is sent to a "satisfactory product" line by the selecting device 20; if the difference is not within the permissible range, the finished coil spring is sent to a "defective product" line.
The permissible difference in the length of the wire material varies depending upon the free length, pitch, number of coils wire diameter and conditions of use, etc. and is determined in accordance with these elements.
In the method of the present invention, the formation of the end-coiling section starts when the position of the end of the pitched coil (or main-coiling section) is detected. Accordingly, the free length of the spring can always be the same as the one set beforehand. Since the length of the end-coiling section is set at a fixed value, and since this value is extremely small compared to the free length of the coil spring, the end-coiling section does not affect the free length of the spring. Accordingly, the precision of the free length of the spring can be kept high.
If a permissible limit is, for example, 0.01 (orΔL/L=0.01) for a coil spring which has a 30 mm free length, almost 100% of the coil springs produced by the method of the present invention fall within the permissible and satisfactory range.
According to the present invention, the coil springs are manufactured with priority given to their free length, and a check is made to see whether or not the wire material length for each coil spring is within a permissible limit. Also, in the present invention, if the wire material length, which affects the performance of the coil springs, for the individual coil spring is different, and if the wire material length is not within the permissible limit, then the pitch tool is immediately fine-adjusted by the control unit so as to correct the problem. In some cases, the correction is made manually after stopping the apparatus. In most cases, the setting of the permissible limit for the wire material length is determined by permissible values of performance of coil spring, but no particular problems are encountered as long as an permissible value is applied.
In the present invention, as described above, defective products are removed in accordance with the length of the used wire material. Also, a prescribed amount of wire material is used for each coil spring, and an error, if any, in the free length of each coil spring would only come from errors in the length of the end-coiling section which can be disregarded in view of coil characteristics. As a result, the precision of the free length of the fabricated coil spring is extremely high, and a desired spring performance is assured. Thus, the required precision of the free length of the coil springs can be kept at a high level, and such satisfactory coil springs can be manufactured at a high rate. | A method of manufacturing coil springs being performed by giving priority to the free length of coil springs with a feature that the length of wire material used for forming initial- and main-coiling sections and an end coiling section of a single coil spring is measured and checked if the used wire material is within a predetermined length so that the resulted coil springs have a high rate of satisfactory products with a high level of precision. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to showerheads and, more specifically, to showerheads able to expel water and at least one substance.
BACKGROUND OF THE INVENTION
[0002] Presently the general concept of supplying soapy water and clean water through separate conduits to a common dispensing device or head, each conduit having a separate orifice or holes exists in the prior art.
[0003] One patent disclosing a dual hose dispenser is U.S. Pat. No. 4,461,052 issued to Mostul which discloses a scrubbing brush having two conduits. The first conduit provides clear water and a second conduit provides soapy water. The second conduit terminates in an orifice, while the first conduit terminates in the nozzle. However, a noted drawback with the Mostul dispenser is the uniform arrangement of dispensing holes in the scrubbing brush.
[0004] Another US patent disclosing a dual hose dispenser is U.S. Pat. No. 6,786,431 issued to Song. Song discloses a washing device for automobiles having a pressure head equipped with a soap water tank and a water pipe with a water nozzle. A switch on the handle controls the soap water and the fresh water openings. Similarly to Mostul, the Song dual hose dispenser also provides a uniform arrangement of dispensing holes, wherein the holes through which the water flows are the same as the holes through which the soap water flows.
[0005] U.S. Pat. No. 4,113,182 issued to Brago discloses a spray gun cleaning system having individual fluid sources connected to a mixing chamber by individual conduits. The output of the mixing chamber is connected to a spray nozzle. This apparatus includes a single set of holes from which the fluids flow. Thus, the single set of holes are not specific to a particular conduit.
[0006] While these devices may be suitable for the purposes for which they were designed, they would not be suitable for the purposes of the present invention, as hereinafter described.
SUMMARY OF THE INVENTION
[0007] An apparatus dispenses at least one fluid. A receiving section includes a first conduit and a second conduit. A dispensing section includes a faceplate, including a first plurality of recesses and a second plurality of recesses. A diameter of each recess of the first plurality of recesses is smaller than a diameter of each recess of the second plurality of recesses. The first conduit is connected to provide a flow of water for dispensing through the first plurality of recesses and the second conduit is connected to provide one of a water or soap and water solution for dispensing through the second plurality of recesses.
[0008] A method for dispensing at least one fluid. A receptacle is connected to a source of water for receiving water in first and second compartments thereof. A soap solution is poured into the second compartment. A first valve is selectively pivoted between a first position allowing water to flow from the first compartment for dispensing through a first and second plurality of apertures in a showerhead. A first valve is selectively pivoted between a second position allowing a soap solution to flow from the second compartment for dispensing through the second plurality of apertures in the showerhead. A first valve is selectively pivoted between a third position allowing water to flow from the first compartment for dispensing through the first plurality of apertures in the showerhead, and the soap solution flows from the second compartment for dispensing through the second plurality of apertures in the showerhead.
[0009] It is an object to provide a dual hose showerhead.
[0010] Another object is to provide a dual hose showerhead having a first hose for transporting water and a second hose for transporting a soap and water solution.
[0011] It is another object to provide a dual hose showerhead that includes a single compartmentalized container wherein water is retained in a first compartment and soap to form the soap and water solution is retained in a second compartment.
[0012] Yet another object is to provide a dual hose showerhead wherein a first plurality of apertures having different sized openings from a second plurality of apertures in a faceplate of the showerhead.
[0013] Still yet another object is to provide a dual hose showerhead having two sets of a plurality of apertures, one set larger than the other and wherein the soap and water solution flows through larger openings of the first and second plurality of apertures.
[0014] It is another object to provide a dual hose showerhead wherein a user selects one of water, a soap and water solution or both water and a soap and water solution to be dispensed through the first and second plurality of apertures.
[0015] Additionally, it is another object to provide a dual hose showerhead that entirely expels the soap residue therefrom and thereby prevents blockage of the plurality of apertures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0016] In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawing in which:
[0017] FIG. 1 is a view of the face of the showerhead nozzle of the dual hose showerhead system;
[0018] FIG. 2 is a side view of the showerhead of the dual hose showerhead system;
[0019] FIG. 3 is a side cross-sectional view of the dual conduit hose and nozzle of the showerhead system;
[0020] FIG. 4 is a cross sectional view of the valve controlling the flow of water into the showerhead of the showerhead system;
[0021] FIG. 5 is a cross sectional view of the dual hose showerhead system;
[0022] FIG. 6 is a cross sectional view of an alternate embodiment of the dual hose showerhead system;
[0023] FIG. 7 is a flow diagram detailing the operation of the dual hose showerhead system;
[0024] FIG. 8 is a flow diagram detailing the operation of the dual hose showerhead system for producing a mix flow of both clean and soapy water;
[0025] FIG. 9 is a flow diagram detailing the operation of the dual hose showerhead system for providing a flow of soapy water; and
[0026] FIG. 10 is a flow diagram detailing the shut down operation of the dual hose showerhead system.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The following discussion describes the present invention. This discussion should not be construed, however, as limiting the invention to that particular embodiment. Practitioners skilled in the art will recognize numerous other embodiments as well.
[0028] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 10 illustrate a dual hose showerhead system which is indicated generally by the reference numeral 10 and which will be referred to hereinafter as “system 10 ”.
[0029] FIG. 1 is a view of the face of the showerhead nozzle of the dual hose showerhead system 10 . Shown herein is a faceplate 18 of the showerhead 12 . The faceplate 18 may include a plurality of first apertures 14 and a plurality of second apertures 16 . Herein, the second apertures 16 may each have larger openings and may be fewer in number than the first apertures 14 . The pattern, shape, and number of individual apertures of each of the plurality of first apertures 14 and the plurality, pattern, shape and number of the individual second apertures 16 are shown for purposes of example. While any number, shape, and pattern of apertures may be used, in the example provided herein, the first apertures 14 may be in the shape, size, and configuration of a typical showerhead and the second apertures are relative to the first apertures 14 significantly larger, six in number. Each of the larger apertures 16 may have a helical configuration with the wider or larger end of each aperture 16 defining an exit port from the faceplate 18 . Clean water may be able to flow through both the first apertures 14 and the second apertures 16 at selected times, as will be described hereinafter with specific reference to FIG. 2 . Additionally, a solution of soap and clean water, hereinafter “soapy water” may only flow through the second apertures 16 . The larger openings of the second apertures 16 with respect to the first apertures 14 allows soap residue to be expelled entirely therefrom and thereby prevent blockage of the second apertures 16 . The manner by which water and soapy water are expelled from the faceplate 18 of the nozzle will be discussed hereinafter with specific reference to FIGS. 2-8 . The aperture openings may take any shape such as, for example, circular, in which instance the larger openings 16 may have a larger diameter than the second set of apertures 16 .
[0030] FIG. 2 is a side view of the dual hose showerhead system 10 . The dual hose showerhead system 10 may include the showerhead 12 attached to a hose sheath 26 . A first conduit 28 and a second conduit 30 may be positioned within the hose sheath 26 and extend substantially parallel thereto, shown in FIG. 3 . The hose sheath 26 may prevent the conduits 28 , 30 from getting tangled with one another. Clean water may flow through the first conduit 28 and soapy water may flow through the second conduit 30 as will be described hereinafter with specific reference to FIG. 4 .
[0031] The faceplate 18 of the showerhead may, as indicated, include the plurality of first apertures 14 and the plurality of second apertures 16 . Also as described above, each of the second apertures 16 may have larger openings and may be fewer in number and helically shaped than the first apertures 14 . Clean water may be able to flow through both the first apertures 14 and the second apertures 16 at selected times, as will be described below. Additionally, soapy water may only flow through the second apertures 16 . The relatively larger openings of the second apertures 16 allow the soapy water and the soapy residue to be expelled entirely therefrom and for preventing blockages of the apertures 16 .
[0032] A user may selectively determine which substance will flow through the first and second apertures 14 , 16 by depressing one of a plurality of buttons 20 , 22 , 24 . Herein the buttons 20 , 22 , 24 may be located on the showerhead 12 . However, this is for purposes of example only and the buttons 20 , 22 , 24 may be located in any location that is easily accessible to the user. Depression of the first button 20 may cause clean water to flow through both the first and second apertures 14 , 16 . Alternatively, clean water flowing through both the first and second apertures 14 , 16 may be the default operation of the dual hose showerhead system 10 . During default operation, when the shower is turned on, clean water may flow through both the first and second apertures 14 , 16 regardless of whether the first button 20 is depressed. Depression of the second button 22 may cause soapy water to flow through the second apertures 16 only. Depression of the third button 24 may cause clean water to flow through the first apertures 14 and soapy water to flow through the second apertures 16 simultaneously.
[0033] FIG. 3 is a cross sectional view of the dual hose showerhead system 10 . The dual hose showerhead system 10 may include the showerhead 12 attached to the hose sheath 26 . The first conduit 28 may extend within the sheath 26 . The first conduit 28 may be connected to a first channel 84 , within the showerhead 12 , via a first valve 64 , as will be described in more detail with respect to FIG. 4 . The first channel 84 may be connected to the plurality of first apertures 14 . Additionally the second conduit 30 may also extend within the sheath 26 . The second conduit 30 may connect to a second channel 86 , within the showerhead 12 , via the first valve 64 . The second channel 86 may be connected to the plurality of second apertures 16 . The hose sheath 26 may prevent the first and second conduits 28 , 30 from getting tangled with one another. Clean water may flow through the first conduit 28 and soapy water may flow through the second conduit 30 as will be described hereinafter with specific reference to FIG. 5 .
[0034] As can be seen from this figure, the faceplate 18 may include the plurality of first apertures 14 and the plurality of second apertures 16 . Each of the second apertures 16 may, as previously discussed, have larger openings relative to the first apertures 14 and may be fewer in number than the first apertures 14 . Clean water may be able to flow through both the first apertures 14 and the second apertures 16 at selected times, as described below. Soapy water may only flow through the second apertures 16 . The larger openings of the second apertures 16 may allow the soap residue from the soapy water to be expelled entirely therefrom and thereby prevent blockage of the apertures 16 .
[0035] FIG. 4 is a cross sectional view of the first valve 64 that may govern the flow of water from the first and second conduits 28 , 30 into the showerhead of the dual hose showerhead system 10 . The conduit 30 for carrying soap-water may have a smaller diameter than the conduit 28 for carrying water. In this way, the soap-water combination in conduit 30 may be under relatively greater pressure than the water in the other conduit 28 . The first valve 64 may connect the hose sheath 26 to the showerhead 12 . The hose sheath 26 may house both the first conduit 28 and the second conduit 30 and may prevent them from getting tangled with one another. The first conduit 28 may be connected to the first valve 64 at a first input port 94 and the second conduit 30 may be connected to the first valve 64 at a second input port 96 . The first valve 64 may house a control box 88 positioned between the first conduit 28 and second conduit 30 having a hinge 90 with a moveable partition 92 attached thereto. The first channel 84 may be connected to the first valve 64 at a first output port 98 and the second channel 86 may be connected to the first valve 64 at a second output port 100 . The first input port 94 may be located on a side of the first valve 64 opposite from and aligned with the first output port 98 and the second input port 96 may be located on a side of the valve opposite from and aligned with the second output port 100 . The control box 88 may control the position of the moveable partition 92 in response to depression of one of the plurality of buttons 20 , 22 , 24 .
[0036] The user may selectively determine the substance flowing through the first and second apertures 14 , 16 by depressing one of the plurality of buttons 20 , 22 , 24 located on the showerhead 12 as discussed hereinbefore. The buttons 20 , 22 , 24 may be located on the outer surface of the showerhead 12 as shown in FIG. 2 . The arrangement of the buttons 20 , 22 , 24 and the configuration of the buttons 20 , 22 , 24 may be one of choice. In the example provided here, the soap button 22 is diamond shaped and disposed, relative to the other buttons 22 , 24 , closer to the faceplate 18 . The water and mix buttons 20 , 24 , respectively, are rectangular in shape and located rearwardly of the faceplate 18 and the soap button 22 . The shape of the soap button 22 and the relative location of the water and mix buttons 20 , 24 may assist the user is distinguishing one button from the other while in use.
[0037] Depression of the water button 20 may cause clean water to flow through the first conduit 28 and into the first valve 64 via the first input port 94 . The moveable partition 92 may move on the hinge 90 as indicated by directional arrow A to cover the second conduit 30 thereby allowing the clean water to flow from the first conduit through both the first channel 84 and the second channel 86 via both the first output port 98 and the second output port 100 . The clean water may flow from the first channel 84 and the second channel 86 through each of the plurality of first apertures 14 and second apertures 16 respectively. Alternatively, the clean water flowing through both the first and second apertures 14 , 16 may be the default operation of the dual hose showerhead system 10 . During default operation, regardless of whether the first button 20 is depressed, when the shower is turned on, the moveable partition 92 may cover the second conduit 30 and the clean water may flow through the first and second channels 84 , 86 , via both the first and second output ports 98 , 100 , and may exit the first and second apertures 14 , 16 respectively.
[0038] Depression of the second or soap button 22 may cause soapy water to flow through the second conduit 30 and into the first valve 64 via the second input port 96 . The moveable partition 92 may be positioned vertically thereby dividing the first valve 64 and permitting the soapy water to flow solely into the second channel 86 via the second output port 100 . The soapy water may flow from the second channel 86 through the plurality of second apertures 16 with a turning stream caused by the helixes.
[0039] Depression of the third or mix button 24 may allow clean water to flow through the first conduit 28 and into the first valve 64 , via the first input port 94 , while simultaneously allowing soapy water to flow through the second conduit 30 and into the first valve 64 via the second input port 96 . The moveable partition 92 may be positioned within the first valve 64 so as to divide the first valve 64 and to permit the clean water to flow solely into the first channel 84 via the first output port 98 and the soapy water to flow solely into the second channel 86 via the second output port 100 . The clean water may flow from the first channel 84 through the plurality of first apertures 14 while the soapy water may flow from the second channel 86 through the plurality of second apertures 16 .
[0040] FIG. 5 is a cross sectional view of the dual hose showerhead system 10 . A water pipe 60 may extend from the shower wall and may be connected to a container 66 at an input port 78 thereof. A second valve 82 may extend from the input port 78 into the pipe 60 for governing the entrance of water from the pipe 60 through the input port 78 and into the container 66 . The pipe 60 may have an L-shape, as is well known in the art, with one leg 61 extending horizontally out of the wall (not shown) and a downward leg 63 . The second valve 82 may include a divider 65 for dividing the flow of water through the input port 78 .
[0041] The container 66 , which may be further secured to the shower wall for support, may include a first compartment 44 and a second compartment 46 . The first compartment 44 may be connected to a first side of the second valve 82 allowing water to flow therein. The first compartment 44 may have an egress port 54 connected to the first conduit 28 . In the embodiment shown herein, the first compartment 44 may retain only clean water from the water pipe 60 . The second compartment 46 may be connected to a second side of the second valve 82 allowing water to flow therein. The second compartment 46 may have an egress port 50 which may be connected to the second conduit 30 . The container 66 may also include an ingress port 56 for providing access to the second compartment 46 . The ingress port 56 may be selectively covered by a cap 58 . The ingress port 56 may permit a user to add soap to the second compartment 46 . The soap can be at least one of liquid or powdered.
[0042] The first conduit 28 and second conduit 30 may be connected to the showerhead 12 at ends opposite connection to the container 66 via the first valve 64 , as described hereinabove with specific reference to FIG. 4 . The faceplate 18 of the showerhead 12 may include the plurality of first apertures 14 and the plurality of second apertures 16 . Herein, each of the second apertures 16 may have larger openings and may also be fewer in number than the first apertures 14 . Clean water may be able to flow through both the first apertures 14 and the second apertures 16 at selected times. Soapy water may only flow through the second apertures 16 . The larger openings of the second apertures 16 may allow the soap residue from the soapy water to be expelled entirely therefrom and thereby prevent blockage of the apertures 16 .
[0043] The user may selectively determine the substance flowing through the first and second apertures 14 , 16 by depressing one of the plurality of buttons 20 , 22 , 24 . The buttons 20 , 22 , 24 may be located on the outer surface of the showerhead 12 . Operation of the dual hose showerhead system 10 was described hereinabove with specific reference to FIG. 4 .
[0044] A showerhead holder 62 may be integrally attached to a side of the container 66 for retaining the showerhead 12 while not in use. Alternatively, the holder 62 may be secured to the downward leg 63 of the L-shaped pipe 60 with the container 66 being so dimensioned so that the showerhead 12 may be easily releasably attached to the holder 62 to the pipe 60 .
[0045] FIG. 6 is a cross sectional view of the dual hose showerhead system 10 . The dual hose showerhead system 10 may include the showerhead 12 attached to the hose sheath 26 . The first conduit 28 and the second conduit 30 may be positioned within and extend through the hose sheath 26 . The hose sheath 26 may prevent the conduits 28 , 30 from getting tangled with one another. The first and second conduits 28 , 30 may be connected to the corresponding first and second channels 84 , 86 within the showerhead 12 via the first valve 64 and pass water therethrough, as described hereinabove with specific reference to FIG. 4 .
[0046] Shown herein the faceplate 18 may cover the showerhead 12 . Herein, a sponge attachment 68 may cover the faceplate 18 . The faceplate 18 may include the plurality of first apertures 14 and the plurality of second apertures 16 . Herein, each of the second apertures 16 may have larger openings and may be fewer in number than the first apertures 14 . Clean water may be able to flow through both the first apertures 14 and the second apertures 16 at selected times, and thereby through the sponge attachment 68 as well. Soapy water may flow through the second apertures 16 . The second apertures 16 may have larger openings than the first apertures 14 thereby allowing the soap residue to be expelled entirely therefrom and for preventing blockages of the apertures 16 .
[0047] The sponge attachment 68 may enable a user to wash and exfoliate with the sponge while clean water, soapy water, or a mix thereof flows therethrough.
[0048] FIG. 7 is a flow diagram describing the operation of the dual hose showerhead system 10 . In step S 100 , a user may turn on the shower. In step S 102 , clean water may flow through the pipe 60 to a first valve. In step S 104 , the user may press the water only button 20 . Pressing the water only button 20 may cause the clean water to flow from the pipe 60 and into the first compartment 44 via the second valve 82 as described in step S 106 . From the first compartment 44 , the clean water may flow through the first conduit 28 as stated in step S 108 . As described in step S 110 , a first valve 64 in the showerhead 12 may enable the clean water to flow from the first conduit 28 through both the first apertures 14 and the second apertures 16 located in the faceplate 18 of the showerhead 12 .
[0049] Alternatively, after the water may flow through the pipe 60 to the first valve in step S 102 , if the soapy water button 22 is not pressed as stated in step S 300 , the dual hose showerhead system 10 may default to step S 106 , as described above, and follows the same steps thereafter. If the soapy water button 22 is pressed in step S 200 , the steps continue as described hereinafter with specific reference to FIG. 8 .
[0050] Alternatively, after the water may flow through the pipe 60 to the first valve in step S 102 , if the mix button 24 is not pressed in step S 300 , the dual hose showerhead system 10 may default to step S 106 , as described above, and follows the same steps thereafter. If the mix button 24 is pressed in step S 300 , the steps may continue as described hereinafter with specific reference to FIG. 9 .
[0051] FIG. 8 is a flow diagram of the dual hose showerhead system 10 describing the steps following step S 200 in FIG. 7 . After the soapy water button 24 is pressed in S 200 , clean water may flow from the pipe 60 and into the second compartment 46 where it mixes with the soap therein as discussed in step S 202 . As stated in step S 204 , the soapy water solution may flow from the second compartment 46 into the second conduit 30 . In step S 206 , the soapy water may then flow from the second conduit 30 , into the showerhead 12 and be expelled through the second apertures 16 located within the faceplate 18 of the showerhead 12 .
[0052] FIG. 9 is a flow chart describing the steps involved in the operation of the dual hose showerhead 10 following step S 300 in FIG. 7 . After pressing the mix button as described in step S 300 , clean water may flow from the pipe 60 and into the first compartment 44 as discussed in step S 302 . From the first compartment 44 , the clean water may flow through the first conduit 28 as described in step S 304 . As stated in step S 306 , the clean water may flow from the first conduit 28 through the showerhead 12 and out of the first apertures 14 in the faceplate 18 of the showerhead 12 . Steps S 302 , S 304 and S 306 occur simultaneously with steps S 303 , S 305 , and S 307 . As discussed in step S 303 , clean water may flow into the second compartment 46 and mix with the soap therein. The soapy water solution may flow from the second compartment 46 and into the second conduit 30 as stated in step S 305 . As described in step S 307 , the soapy water may flow from the second conduit 30 , into the showerhead 12 and be expelled through the second apertures 16 located within the faceplate 18 of the showerhead 12 .
[0053] FIG. 10 is a flow diagram describing the process of turning off the dual hose showerhead system 10 . As discussed in step S 400 , the shower may be turned off. In step S 402 , a third valve may prevent the water remaining in the first compartment 44 from exiting the first compartment. As stated in step S 403 , which occurs simultaneously with step S 402 , the remaining water in the second compartment 46 may flow through the second conduit 30 and exit the dual hose showerhead system 10 through the second apertures 16 located within the faceplate 18 of the showerhead 12 . As described in step S 404 , water remaining in the first compartment 44 may flow through the first conduit 28 . The valve in the showerhead 12 may enable the clean water to flow from the first conduit 28 through the second apertures 16 in the faceplate 18 , thereby removing the soapy residue that could build-up in the second apertures 16 .
[0054] The dual hose showerhead system 10 may allow users to shower with shampoo and rinse off by the push of a few buttons, rather than fumbling with a plurality of bottles. Alternatively, at least one of the compartments can be filled with a body wash, instead of a shampoo. This is especially useful in terms of the elderly, people bathing small children and people bathing pets.
[0055] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of devices differing from the type described above.
[0056] While certain novel features have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
[0057] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | An apparatus and method for dispensing at least one fluid. A receiving section includes a first conduit and a second conduit. A dispensing section includes a faceplate, including a first plurality of recesses and a second plurality of recesses. A diameter of each recess of the first plurality of recesses is smaller than a diameter of each recess of the second plurality of recesses. The first conduit is connected to provide a flow of water for dispensing through the first plurality of recesses and the second conduit is connected to provide one of a water or soap and water solution for dispensing through the second plurality of recesses. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to frames, racks or stands, and more specifically to stands used to safely support large and heavy materials, including slabs, frames or trusses containing marble, granite, glass, sheet metal or wood.
BACKGROUND OF THE INVENTION
[0002] The handling of large heavy slabs of material, such as marble or granite, can be labor intensive and dangerous. An individual slab of marble may weigh as much as 1,200 pounds. To move an individual slab, the handler attaches a lifting clamp or similar device to the top edge of the slab. The clamp may be connected to a crane, an overhead winch, a fork lift or other lifting means. Once the clamp is attached to the slab, the slab can be lifted from its position and moved to a desired location.
[0003] Attachment of the clamp to the top edge of the slab is often difficult. Many times, the slab is leaned up against a wall or object, with the top edge of the slab resting flush against the adjacent wall or object. To place the clamp around the top edge, the slab must be tilted away from the wall or object to create adequate clearance for the clamp.
[0004] In many cases, the handlers tilt the slab by hand, insert a spacing block between the slab and the adjacent surface, and then lean the slab back against the spacing block to establish a clearance between the top edge of the slab and the adjacent wall or object. This method requires at least two laborers to complete, due to the weight of the slab. In addition, the method is very cumbersome. Some slabs have a height of over six feet, making it difficult to tilt the slab and place the spacing block behind the slab. Once the spacing block is placed, the block can fall down between the slab and the adjacent wall or object, allowing the top edge to fall back against the wall or object. Moreover, there may be insufficient space for two laborers to work around the slab. For instance, slabs may be delivered on a fully loaded flat bed truck. In such cases, laborers must stand on narrow ledges on the truck bed to maneuver the slabs and prepare them for lifting.
[0005] Aside from its difficulties, the method described above is very dangerous. The handler who holds the slab in a tilted position can lose grip on the slab or be overcome by the slab's weight if the slab is tilted too much. The handler who reaches behind the slab to place the spacing block risks crushing a finger or an arm if the slab falls back against the adjacent wall or object. As a result, this method has many problems regarding implementation and worker safety.
SUMMARY OF THE INVENTION
[0006] With the foregoing in mind, the present invention provides an apparatus for safely holding a heavy slab. In particular, the present invention holds a slab away from adjacent walls or objects to allow a lifting clamp to be attached to the top edge of the slab. The apparatus includes a light-weight free-standing frame or stand that safely holds a slab in a tilted position to allow a handler to attach a lifting clamp to the slab. Since the stand safely holds the slab, one person can tilt the slab and attach the lifting clamp to the slab without any assistance. The stand is compact so that it can easily be lifted and used in areas where space is limited, such as the edge of a flat bed truck. The present invention also includes a method for safely placing a slab in a tilted position on a stand to allow attachment of a lifting clamp to the slab.
[0007] The apparatus preferably includes a base member attached to the midpoint of a cross member, forming a T shape. A front support member extends generally vertically from the midpoint of the cross member. The front support member is braced by a rear support member that extends from the rear end of the base member up to a point along the mid span of the front support member. A toe plate is connected to the front of the cross member and extends forwardly from the apparatus to be inserted beneath a slab. The toe plate and front support member are pitched so as to allow the slab to be leaned against the stand at a small angle. In this position, the slab's force on the stand is significantly small relative to the weight of the slab.
DESCRIPTION OF THE DRAWINGS
[0008] All of the objects of the present invention are more fully set forth hereinafter with reference to the accompanying drawings, wherein: FIG. 1 is an elevation view of the preferred embodiment prepared for use; FIG. 2 is a frontal view of the device in FIG. 1; and FIG. 3 is an elevation view of the device in FIG. 1 illustrating the operation of the device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0009] Referring now to FIGS. 1 - 3 in general and to FIG. 1 specifically, there is shown a stone stand 10 having a base 20 and a support frame 30 that extends generally vertically from the base to form a rigid stand. The stand 10 is compact and light-weight so that it can be easily lifted and maneuvered. A toe plate 40 extends forwardly from the base 20 and is configured to be inserted beneath a slab of material 5 . Prior to being lifted, the slab 5 is positioned so that the bottom edge of the slab is raised above the floor. In FIG. 1, the slab is raised off the floor using wooden shims 2 .
[0010] The stand 10 is compact, which allows the stand to be used in areas where space is limited. For instance, when slabs are off-loaded from flat bed trucks, the slabs take up much of the truck bed, so that workers must stand on narrow ledges to maneuver the slabs. The stone stand 10 is compact enough to be used safely on narrow ledges. The base 20 is formed by two members, which take up very little floor space.
[0011] Referring to FIGS. 1 - 2 , the construction of the base 20 is shown. The base 20 is formed by a base member 22 attached to a cross member 24 . Preferably, the base member 22 is attached to an edge of the cross member 24 such that the end of the base member is connected at the midpoint of the cross member. Preferably, the length of the base member 22 is eighteen inches or shorter, so that the stand 10 may be used on narrow ledges or other areas having limited floor space.
[0012] Referring again to FIG. 1, the support frame 30 includes an elongated vertical front support member 32 and a rear support member 34 connected to the rear edge of the front support member. The front support member 32 extends generally vertically from the midpoint of the top edge of the cross member 24 . The front support member 32 forms an acute angle 38 relative to a vertical axis extending from the lower end of the front support member, as shown by the dashed line in FIG. 1. Preferably, the angle 38 is between 5 and 10 degrees.
[0013] The rear support member 34 extends upwardly from the base 20 and is connected to the front support member 32 to act as a brace for the front support member. More specifically, the rearward end of rear support member 34 is mitered to rest flush against the top edge of the base member 22 near the rearward end of the base member. The rear support member 34 extends upwardly and forwardly from the rearward end of the base member 22 . The forward end of rear support member 34 is mitered to adjoin the rearward edge of front support member 32 and form a brace joint 36 . The brace joint 36 divides the front support member 32 into an upper span 42 and a lower span 44 .
[0014] The toe plate 40 extends from the midpoint of the front edge of the cross member 24 , as illustrated in FIG. 1. The toe plate 40 is an L-shaped member that includes a bottom plate 46 and a back plate 48 generally perpendicular to the bottom plate. Preferably, the front edge of the front support member 32 is flush with the front edge of cross member 24 to form an even surface for mounting the toe plate 40 . The toe plate 40 is connected to the front support member 32 and cross member 24 to form a continuous bottom edge with the bottom edge of the base 20 . More specifically, the toe plate 40 is mounted so that the bottom edge of the bottom plate 46 is generally flush with the bottom edges of the cross member 24 and base member 22 to provide stability and minimize rocking of the stand 10 . The back plate 48 generally conforms to the small tilt angle 38 of the front support member 32 , such that the bottom plate 46 is pitched slightly upwardly as it extends away from the front support member. This incline assists in urging the slab 5 toward a leaning position on the stand 10 .
[0015] Referring now to FIG. 3, the slab 5 is shown leaning against the stand 10 . For clarity, the shims 2 are omitted from FIG. 3. When the slab 5 is leaned against the stand 10 , the top edge of the slab 5 preferably extends above the front support member 32 . In this way, the top of the front support member 32 does not obstruct the top edge of the slab 5 and interfere with the attachment of the lifting clamp. The front support member 32 is configured to receive the slab 5 in a leaning position with the face of the slab flush against the front support member 32 . The slab leans at an angle conforming with the tilt angle 38 of the front support member. In this position, the slab has a center of gravity 6 located at a vertical distance above the base 20 .
[0016] The slab 5 exerts a force against the support frame 30 in response to gravity. The force is generally distributed uniformly along the length of the front support member 32 . The tilt angle 38 of the front support member 32 , which generally defines the angle of the slab 5 when the slab is placed on the stand, is very small, preferably ranging between 5 and 10 degrees. Since the slab 5 leans at a small angle on the stand 10 , substantially all of the slab's weight is distributed downwardly, and only a small fraction of the slab's weight bears against the support frame 30 .
[0017] When the slab 5 is leaned against the stand 10 , the force that bears against the front support member 32 creates a moment about the midpoint of cross member 24 . This moment urges the front support member 32 to rotate or bend rearwardly. To counterbalance the slab's force on the front support member 32 , the brace joint 36 is preferably positioned so that the joint is higher than the center of gravity of the slab 5 . Moreover, the axial length of the upper span 42 is preferably less than the axial length of the lower span 44 . This gives the support frame 30 stability and limits deflection of the front support member 32 when the slab 5 is leaned on the stand 10 .
[0018] The brace joint 36 is also positioned to provide rigidity in the lower span 44 . When shorter slabs are leaned against the stand 10 , there is a potential for buckling or bending in the lower span 44 . This is especially true if the height of the slab is shorter than the length of the lower span 44 . In such a case, the slab's force on the front support member 32 will be absorbed entirely by the lower span 44 . As the ratio of the lower span's length to the thickness of the front support member 32 increases, the potential for buckling in the lower span increases. Therefore, preferably the brace joint 36 is located near the midpoint of the front support member 32 to limit the length of the lower span 44 . More specifically, preferably, the distance between the brace joint 36 and midpoint of the front support member 32 is substantially smaller than the distance between the brace joint and upper end of the front support member.
[0019] The base member 22 , cross member 24 , front support member 32 and rear support member 34 are constructed out of strong light-weight materials, such as corrosion-resistant square steel tubing. Preferably, the ends of the steel tubing contain caps to seal off the interior of the tubing and prevent moisture from entering the tubing. The toe plate 40 is formed of a strong material, such as a three eighth inch steel plate or bracket, capable of supporting a slab without deflection. The aforementioned components can be connected using a variety of conventional joining methods, including welding or bolts.
[0020] Referring now to FIG. 3, the operation of the stand 10 will be described. The slab 5 to be lifted is initially tilted on its side and placed on shims, beams or the like so that the bottom edge of the slab is raised above the floor. The stand 10 is then inserted beneath the slab 5 and centered so that the toe plate 40 is generally adjacent to the midpoint of the slab's bottom edge. Where the clearance between the slab 5 and floor is small, the stand 10 may be tilted forward as necessary so that the inclined bottom plate 46 can be inserted beneath the slab. The stand 10 is positioned so that the cross member 24 is generally parallel to the front face orientation of the slab 5 .
[0021] Once the toe plate 40 is beneath the slab 5 , the stand 10 is maneuvered under the slab until that the back plate 48 of toe plate 40 abuts the face of the slab, as shown in FIG. 3. Preferably, the vertical clearance between the bottom plate 46 and the slab is no more than one half inch. However, it is not crucial that the bottom edge of the slab 5 contact the bottom plate 46 , since the shims will continue to support the slab. Once the stand 10 is in place, the slab 5 is slowly tilted in the direction marked A in FIG. 3. The slab is then leaned on the front support member 32 so that a lifting clamp can be attached to the top edge of the slab. The lifting clamp is then raised vertically to lift the slab.
[0022] The terms and expressions which have been employed are used as terms of description and not of limitation. There is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof. It is recognized that various modifications are possible within the scope and spirit of the invention. For instance, the device may include a flat steel toe plate fixed to the underside of the base as opposed to the L shaped toe plate 40 described above. This toe plate would provide a uniform planar surface to support the stand and minimize rocking. Accordingly, the invention incorporates variations that fall within the scope of the following claims. | A safety stand for safely holding a heavy slab of material is provided. The stand is configured so that a heavy slab can be safely leaned against it. Once the slab is leaned against the stand, the top edge of the slab is in a position such that a lifting clamp or similar device can be attached to the slab. With the stand in place, one person can safely prepare the slab for lifting. | 4 |
GOVERNMENT INTEREST
[0001] This invention was made with government support under Contract No. DE-FC07-05ID14636 awarded by the Department of Energy. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to nuclear reactor internals and more specifically to apparatus for maintaining the alignment of the nuclear reactor internals.
[0004] 2. Description of the Prior Art
[0005] The primary side of nuclear reactor power generating systems which are cooled with water under pressure comprises a closed circuit which is isolated from and in heat-exchange relationship with a secondary side for the production of useful energy. The primary side comprises the reactor vessel enclosing a core internals structure that supports a plurality of fuel assemblies containing fissile material, the primary circuit within heat exchange steam generators, the inner volume of a pressurizer, pumps and pipes for circulating pressurized water; the pipes connecting each of the steam generators and pumps to the reactor vessel independently. Each of the parts of the primary side comprising a steam generator, a pump and a system of pipes which are connected to the vessel form a loop of the primary side. The primary side is also connected to auxiliary circuits, including a circuit for volumetric and chemical monitoring of the pressurized water. The auxiliary circuit, which is arranged branching from the primary circuit, makes it possible to maintain the quantity of water in the primary circuit by replenishing, when required, with measured quantities of water, and to monitor the chemical properties of the coolant water, particularly its content of boric acid, which is important to the operation of the reactor.
[0006] The average temperature of the core components during full power reactor operation is approximately 580 F (304° C.). Periodically, it is necessary to shut down the reactor system for maintenance and to gain access to the interior side of the pressure vessel. During such an outage, the internal components of the pressure vessel can cool to a temperature of approximately 50° F. (10° C.). The internal components of the pressure vessel typically consist of upper and lower internals. The upper internals include a control rod guide tube assembly, support columns, conduits for instrumentation which enter the reactor vessel through the closure head, and a fuel assembly alignment structure, referred to as the upper core plate. The lower internals include a core support structure referred to as the core barrel, a core shroud that sits inside the core barrel and converts the circular interior of the barrel to a stepped pattern that substantially corresponds to the perimeter profile of the fuel assemblies that constitute the core supported between a lower core support plate and the upper core plate. As an alternate to the shroud, a bolted baffle former structure consisting of machined horizontal former and vertical baffle plates, has been employed. It is particularly important to maintain a tight alignment of the reactor internals upper core plate and a top plate of the shroud with the control rod drive mechanisms to assure that the control rods can properly scram; i.e., drop into the core, when necessary. This is particularly challenging when one considers the thermal expansion and contraction that has to be accommodated through power ramp-up and cool down sequences, where temperatures can vary between 50° F. (10° C.) and 580° F. (304° C.)
[0007] In conventional designs, lateral alignment of the upper internals components was accomplished with a series of single pins located around the circumference of the core barrel. The upper core plate alignment pins fit in notches in the upper core plate and locate the upper core plate laterally with respect to the lower internals assembly. The pins must laterally support the upper core plate so that the plate is free to expand radially and move axially during differential thermal expansions between the upper internals and the core barrel. FIG. 1 is a simplified cross-section of such a conventional reactor design. A pressure vessel ( 10 ) is shown enclosing a core barrel ( 32 ) with a thermal shield ( 15 ) interposed in between. Some plants have neutron pads in lieu of the thermal shield. The core barrel ( 32 ) surrounds the core ( 14 ) which is held in position by an upper core plate ( 40 ). The upper core plate ( 40 ) is aligned by the alignment pins ( 19 ) which extend through the core barrel ( 32 ) into notches ( 21 ) in the upper core plate ( 40 ). The notches ( 21 ) permit the core barrel to grow with thermal expansion at a greater rate than the upper core plate ( 40 ) during start up without compromising the lateral position of the upper core plate ( 40 ). The installation sequence of the core shroud ( 17 ) in new advanced passive plant designs requires a modified design that will prevent lateral movement of the upper core plate and the core shroud while enabling thermal growth and differential expansion between both the shroud and the upper core plate and the core barrel, while maintaining rotational stability.
[0008] New passive nuclear plant designs employ a core shroud assembly that is primarily a welded structure. The typical manufacturing process is to assemble the core shroud fully outside the lower internals core barrel. After assembly, the core shroud assembly is lowered into the lower internals. In this arrangement, it is not possible to have protruding alignment pins ( 19 ) to engage the upper internal's core plate. The protruding alignment pins would interfere with the core shroud bottom plate, core shroud panel reinforcements, etc., during insertion within the core barrel. Therefore, an alternate alignment feature was identified to accommodate the advanced passive plant internals design.
[0009] To align the core shroud and upper internals this alternate alignment feature comprises four alignment plates, secured to the lower internals core barrel with a set of bolts and dowel pins. The alignment plates are installed after installation of the core shroud assembly within the lower internals. Custom fit inserts are used to align both the lower and upper internals with each other via the alignment plates. However, the installation of the alignment plates involves machining four slots, or grooves, in the inside diameter of the core barrel; one groove is required for each alignment plate. The grooves are required to verify set up of the alignment plates prior to installation of the core shroud assembly. The alignment plates are installed in the lower internals after installation of the core shroud assembly. To provide clearance to slide the alignment plate into the machined groove in the core barrel inside diameter, the core shroud top plate slot depth is increased 0.750″ (1.905 centimeters), as compared to nominal value. This 0.750″ (1.905 centimeter) increase occurs at a location adjacent to one of the more limiting core shroud top plate ligaments. After securing each alignment plate with dowel pins and six bolts, the 0.750″ (1.905 centimeter) gap between the alignment plate and the core shroud top plate is filled by installation of a customized insert. In view of the installation sequence for installing the alignment plates, it's likely that it may be difficult to remove the core shroud assembly, should there be a need during the 60 year design life of the advance passive plant designs. Accordingly, an alternate design is desired that would further facilitate manufacture, installation and removal of the core internals while maintaining rotational alignment between the core shroud and the upper core plate.
[0010] It is an object of this invention to provide such a further improvement that will additionally facilitate manufacture, satisfy the alignment requirements and permit later removal of the core shroud assembly in tact.
SUMMARY OF THE INVENTION
[0011] In addition to providing features to assure that the upper internals of the reactor vessel are aligned with lower internals during installation, desirably the design of the reactor internals should also include features that facilitate the removal of both lower and upper internals without extensive field operations. This invention presents a design that both aligns the upper core plate with the core shroud and does not require hardware removal when preparing the core shroud for removal from the lower internals. The basic alignment features of this invention comprise a plurality of jacking blocks peripherally spaced around the top plate of the core shroud; jacking studs radially outwardly extending from the jacking blocks; and alignment posts vertically extending and peripherally spaced around the top plate of the core shroud spaced from the jacking blocks.
[0012] When assembled together each combination of a jacking block and a jacking stud form a jacking block assembly. The jacking block assemblies and alignment posts are installed on the top plate of the core shroud and secured with full penetration welds. Anywhere from eight to sixteen jacking block assemblies would be evenly distributed azimuthally around the core shroud centerline. Preferably, the number of jacking block assemblies would be between 12 and 16. Four alignment posts, 90 degrees apart, would be placed azimuthally around the core shroud centerline to engage openings in the upper core plate from the underside.
[0013] The main purpose of the jacking block assemblies is to center, or align, the core shroud top plate within the core barrel during final assembly at manufacturing. Alignment is made by adjusting the radial extension of the threaded jacking studs that extend radially outward from mating threaded openings in the jacking blocks. After final positioning, the threads of the jacking studs are preferably “staked” or “spot” welded to the jacking blocks to lock the studs into position. During reactor operation, the loads at the top of the core shroud would be carried radially via the jacking studs to the core barrel. A hard surface liner formed from a material such as stellite is preferably welded to the core barrel inner surface opposite the jacking studs to accommodate the relative movement of the studs and the core barrel due to the different rates of thermal expansion and contraction over the range of reactor operating temperatures.
[0014] During installation of the upper internals over the lower internals, chamfered lead-in surfaces on the alignment posts will assure proper alignment of the upper core plate inserts prior to engagement of upper core plate fuel guide pins with the fuel assembly top nozzles. Preferably radial guides or bumpers extend from the peripheral surface on the outside diameter of the upper core plate, that are spaced circumferentially to provide additional guidance for the upper core plate within the lower internals core barrel during installation. The thickness of these bumpers may also be customized so that the in-plane loading of the upper core plate during reactor operation can be transferred as a radial load to the core barrel.
[0015] Preferably, each alignment post has a radially outwardly extending bumper to provide a shared load path for in-plane upper core plate loads which are transferred to the core barrel. The bumper can be formed from an insert on the backside of the alignment post and the thickness would be determined from “as built” measurements of the mating hardware. Alternately, the bumper on the alignment post can be replaced or supplemented with a jacking stud similar to that provided on the jacking block assemblies. Desirably, the front end of the stud is rounded to engage the core barrel while the back end of the stud has a machined contour that can be engaged by an installation tool. The outside circumference of the alignment post stud is threaded to engage mating threads in the alignment post. After installation of the core shroud assembly, the jacking studs in the alignment posts can be adjusted to achieve the desired gap with the core barrel. A hole is provided in the backside of the alignment post for the installation tool to engage the jacking stud for adjustment. Preferably, a locking feature such as a locking cup or tack weld is used to secure the jacking stud in place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A further understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
[0017] FIG. 1 is a cross-sectional view of a nuclear reactor vessel showing the pressure vessel, thermal shield, core barrel, core shroud and the core fuel assemblies;
[0018] FIG. 2 is a simplified schematic of a nuclear reactor system to which this invention may be applied;
[0019] FIG. 3 is an elevational view, partially in section, of a nuclear reactor vessel and internal components to which this invention may be applied;
[0020] FIG. 4 a is a perspective view of a core shroud jacking block of this invention;
[0021] FIG. 4 b is a perspective view of a core shroud jacking stud of this invention;
[0022] FIG. 4 c is a perspective view of a core shroud jacking block assembly with a jacking stud shown threaded inside the jacking block;
[0023] FIG. 5 is a perspective view of an alignment post of this invention;
[0024] FIG. 6 is a perspective view of a jacking block assembly and alignment post installed on a core shroud top plate with the core shroud vertical plates that extend down from the core shroud top plate removed for simplicity;
[0025] FIG. 7 is a perspective view of a portion of the core shroud top plate shown inside a portion of the core barrel and illustrates a jacking block assembly aligning the core shroud top plate within the core barrel;
[0026] FIG. 8 a is a perspective view illustrating the engagement of the upper internals upper core plate notch with an alignment post;
[0027] FIG. 8 b is a perspective view of the upper core plate fully engaged with the lower internals core shroud top plate;
[0028] FIG. 9 is a perspective view of a peripheral section of the upper core plate showing a radial bumper on a portion of the upper core plate's circumference;
[0029] FIG. 10 is a perspective view of the upper core plate engaging an alignment post with inserts added on the sides and back of the upper core plate slot;
[0030] FIG. 11 is a perspective view of two threaded jacking studs for an alignment post showing a rounded front section and articulated rear section;
[0031] FIG. 12 is a perspective view of an alignment post modified for a threaded jacking stud;
[0032] FIG. 13 is a cross-sectional view of an upper core plate, alignment post and shroud top plate assembly showing a cross-section of the jacking stud mounted in the alignment post in juxtaposition to the core barrel; and
[0033] FIG. 14 is a cross-sectional view of an upper core plate, alignment post and top shroud plate assembly of FIG. 13 , showing an alternated arrangement in which the alignment post is affixed to the upper core plate and extends downward through a slot in the shroud top plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring now to the drawings, FIG. 2 shows a simplified nuclear reactor primary system, including a generally cylindrical reactor pressure vessel ( 10 ) having a closure head ( 12 ) enclosing a nuclear core ( 14 ). A liquid reactor coolant, such as water, is pumped into the vessel ( 10 ) by pumps ( 16 ) through the core ( 14 ) where heat energy is absorbed and is discharged to a heat exchanger ( 18 ), typically referred to as a steam generator, in which heat is transferred to a utilization circuit (not shown), such as a steam-driven turbine generator. The reactor coolant is then returned to the pump ( 16 ), completing the primary loop. Typically, a plurality of the above-described loops are connected to a single reactor vessel ( 10 ) by reactor coolant piping ( 20 ).
[0035] An exemplary reactor design is shown in more detail in FIG. 3 . In addition to a core ( 14 ) comprised of a plurality of parallel, vertical co-extending fuel assemblies ( 22 ), for purposes of this description, the other vessel internal structures can be divided into the lower internals ( 24 ) and the upper internals ( 26 ). In conventional designs, the lower internals function is to support, align and guide core components and instrumentation, as well as direct flow within the vessel. The upper internals restrain or provide a secondary restraint for the fuel assemblies ( 22 ) (only two of which are shown for simplicity), and support and guide instrumentation and components, such as control rods ( 28 ).
[0036] In the exemplary reactor shown in FIG. 3 , coolant enters the vessel ( 10 ) through one or more inlet nozzles ( 30 ), flows downward through an annulus between the vessel and the core barrel ( 32 ), is turned 180° in a lower plenum ( 34 ), passes upwardly through a lower support plate ( 37 ) and a lower core plate ( 36 ) upon which the fuel assemblies ( 22 ) are seated and through and about the assemblies. In some designs the lower support plate ( 37 ) and lower core plate ( 36 ) are replaced by a single structure, the lower core support plate, at the same location as ( 37 ). The coolant flow through the core and surrounding area ( 38 ) is typically large, on the order of 400,000 gallons per minute at a velocity of approximately 20 feet per second. The resulting pressure drop and frictional forces tends to cause the fuel assemblies to rise, which movement is restrained by the upper internals, including a circular upper core plate ( 40 ). Coolant exiting the core ( 14 ) flows along the underside of the upper core plate and upwardly through a plurality of perforations ( 42 ). The coolant then flows upwardly and radially to one or more outlet nozzles ( 44 ).
[0037] The upper internals ( 26 ) can be supported from the vessel or the vessel head and include an upper support assembly ( 46 ). Loads are transmitted between the upper support assembly ( 46 ) and the upper core plate ( 40 ), primarily by a plurality of support columns ( 48 ). A support column is aligned above a selected fuel assembly ( 22 ) and perforations ( 42 ) in the upper core plate ( 40 ).
[0038] Rectilinearly moveable control rods ( 28 ) typically include a drive shaft ( 50 ) and a spider assembly ( 52 ) of neutron poison rods that are guided through the upper internals ( 26 ) and into aligned fuel assemblies ( 22 ) by control rod guide tubes ( 54 ). The guide tubes are fixedly joined to the upper support assembly ( 46 ) and connected by a split pin ( 56 ) force fit into the top of the upper core plate ( 40 ). The pin configuration provides for ease of guide tube assembly and replacement if ever necessary and assures that core loads, particularly under seismic or other high loading accident conditions are taken primarily by the support columns ( 48 ) and not the guide tubes ( 54 ). This assists in retarding guide tube deformation under accident conditions which could detrimentally affect control rod insertion capability.
[0039] Though not shown in FIG. 3 , the design of this invention includes a core shroud positioned inside the circular core barrel ( 32 ) that converts the inner profile of the core barrel to a stepped circumferential profile that matches the peripheral outline of the fuel assemblies ( 22 ) within the core. A portion of the shroud's stepped inner circumferential profile can be observed in FIG. 6 , which provides a perspective view of a portion of the top plate ( 90 ) of the core shroud assembly ( 88 ), with the alignment features of this invention. The vertical shroud panels that extend down from each of the stepped profiles on the inner periphery of the core shroud top plate ( 90 ), to surround the core, are not shown for simplicity. The core shroud top plate ( 90 ) is shown in FIG. 6 with two jacking block assemblies ( 98 ) circumferentially spaced on either side of an alignment post ( 100 ). The jacking block assemblies ( 98 ) are circumferentially positioned at the periphery of the core shroud top plate ( 90 ). There are anywhere from approximately eight to sixteen jacking block assemblies equally spaced around the circumference of the periphery of the core shroud top plate ( 90 ). The jacking block assemblies ( 98 ) are used to center the core shroud assembly ( 88 ) within the core barrel ( 32 ). The alignment post ( 100 ) of which there are preferably four equally spaced around the circumference of the periphery of the core shroud top plate ( 90 ) are used to align the upper core plate ( 40 ) with the core shroud assembly ( 88 ).
[0040] Accordingly, the alignment system of this invention basically consists of three main components: (i) jacking blocks ( 94 ); (ii) jacking studs ( 96 ); and (iii) alignment posts ( 100 ). When assembled together, the jacking block ( 94 ) and the jacking stud ( 96 ) form a jacking block assembly ( 98 ) which can be better observed from the perspective view shown in FIG. 4 c . The jacking block alone is shown in FIG. 4 a and is constructed from a metal block ( 110 ), such as stainless steel with a threaded hole ( 102 ) centered through it. A stem ( 104 ) extends below the block ( 110 ) and is closely received within a hole in the core shroud top plate ( 90 ) and secured therein by a full penetration weld. The jacking stud ( 96 ) is shown in FIG. 4 b and has a circumferential thread ( 106 ) that mates with the thread in the threaded hole ( 102 ) in the jacking block ( 94 ). The jacking stud ( 96 ) has an articulated rear end ( 108 ) which mates with a complimentary recess in an installation tool that can be used to turn the jacking stud ( 96 ) within the threaded hole ( 102 ) in the jacking block assembly ( 98 ).
[0041] As previously stated the main purpose of the jacking block assemblies ( 98 ) is to center, or align the core shroud assembly ( 88 ) within the core barrel ( 32 ) during final assembly at manufacturing. Alignment is made by adjusting the threaded jacking studs ( 96 ). After final positioning, the threads ( 106 ) of the jacking stud ( 96 ) are “staked” or “spot” welded to the jacking block ( 94 ). During reactor operation, the loads at the top of the core shroud assembly ( 88 ) would be carried radially via the jacking studs ( 96 ) to the core barrel ( 32 ). As can be seen in FIG. 7 , preferably a hard surface ( 92 ) such as stellite is affixed to the inside surface of the core barrel ( 32 ), such as by welding, in the area that abuts the radially outward end of the jacking stud ( 96 ). The size of the hard surface ( 92 ) that interfaces with the jacking stud ( 96 ) should be large enough to accommodate the differential thermal expansion of the core shroud assembly ( 88 ) and the core barrel ( 32 ) as shown in FIG. 7 , so that the abutting end of the jacking stud ( 96 ) remains in contact with the hard surface ( 92 ) through all phases of reactor operation.
[0042] The alignment post ( 100 ) is best shown in FIG. 5 . The alignment post ( 100 ) has a chamfered upper end ( 112 ) that tapers outwardly to a vertical side wall ( 114 ) that extends approximately halfway down the alignment post. The vertical wall ( 114 ) at an end opposite the chamfer ( 112 ) has a lower section ( 116 ) that extends outward to form an acute angle with the base ( 120 ). Similar to the jacking block assemblies ( 98 ) the alignment post ( 100 ) has a welding stem ( 122 ) that extends from the base ( 120 ) and is received in a corresponding opening in the top plate ( 90 ) of the core shroud assembly ( 88 ) where it is secured by a full penetration weld. A bumper ( 124 ) extends from the radial outward face ( 126 ) of the alignment post ( 100 ) as will be explained in greater detail hereafter. During installation of the upper internals within the lower internals, the chamfered (lead-in) surfaces ( 112 ) on the alignment post ( 100 ) will assure proper alignment of the upper core plate ( 40 ) inserts ( 118 ) prior to engagement of the upper core plate ( 40 ) fuel guide pins with the fuel assembly top nozzles as can be seen from FIG. 8 a . Though the alignment post ( 100 ) is shown as being received within a slot ( 128 ) in the upper core plate ( 40 ), it should be appreciated that the alignment post ( 100 ) can also be situated radially inward from the edge of the core shroud top plate ( 90 ) and be received within a hole in the upper core plate ( 40 ) instead of the slot ( 128 ) without departing from the intent of this invention. The final installed configuration of the upper core plate ( 40 ) with the lower internals is illustrated in FIG. 8 b.
[0043] FIG. 9 shows a guide or bumper ( 130 ) that radially extends from the edge of the upper core plate ( 40 ) to provide additional guidance for the upper core plate ( 40 ) as it is lowered within the lower internals core barrel ( 32 ) during installation. The radial thickness of this bumper ( 130 ) may be also customized so that the in-plane loading of the upper core plate during reactor operation can be transferred as a radial load to the core barrel ( 32 ). As noted with regard to FIG. 5 , the alignment post ( 100 ) is designed with a bumper ( 124 ). The purpose of the bumper ( 124 ) is to provide a shared load path for in-plane upper core plate loads. The thickness (i.e., the radial extent) of the bumper ( 124 ) would also be determined from “as built” measurements of the mating hardware. If necessary, the upper core plate ( 40 ) could also be designed to include an additional insert ( 119 ) on the backside of the slots ( 128 ) as illustrated in FIG. 11 .
[0044] An alternate design for the bumper ( 124 ) on the alignment post ( 100 ) is shown in FIGS. 11 and 12 . FIG. 11 shows two perspectives of the alignment post jacking stud ( 132 ) to provide views of the front ( 134 ) and rear ( 136 ) of the jacking stud ( 132 ). The front end ( 134 ) of the stud ( 132 ) is rounded to engage the core barrel ( 32 ) on its inner circumference while the back end ( 136 ) of the stud ( 132 ) has a machined recess ( 138 ) that engages a complimentary shaped tool to facilitate turning the stud during installation. The outside circumference of the stud ( 132 ) is threaded to engage into mating threads in a recess ( 140 ) in the radial outward face ( 126 ) of the alignment post ( 100 ) as shown in FIG. 12 . After installation of the core shroud assembly ( 88 ), the jacking studs ( 132 ) on the alignment post ( 100 ) can be adjusted to achieve the desired gap with the core barrel. A hole ( 142 ) is provided in the backside of the alignment post ( 100 ) for a tool to engage the jacking stud ( 132 ) for adjustment. FIG. 13 shows a cross-sectional view of the core shroud top plate ( 90 ) and upper core plate ( 40 ) taken along a vertical plane that dissects an alignment post ( 100 ) and shows a jacking stud ( 132 ) in Juxtaposition to the core barrel ( 32 ). The front face ( 134 ) of the jacking studs ( 132 ) on the alignment post ( 100 ) and the radial outward face of the jacking studs ( 96 ) on the jacking block assemblies ( 98 ) both abut a hardened surface ( 92 ) such as stellite, on the core barrel ( 32 ). As previously mentioned, the hard surface ( 92 ) should be large enough to accommodate the differential thermal expansion between the core shroud assembly ( 88 ) and the core barrel ( 32 ). FIG. 14 shows an alternate configuration in which the alignment post ( 100 ) is affixed to the underside of the upper core plate ( 40 ) by, for example a full penetration weld, and the lower portion of the alignment post ( 100 ) extends downward through a slot in the core shroud top plate ( 90 ). In all other respects the configuration shown in FIG. 14 is the same as that shown in FIG. 13 .
[0045] Accordingly, the alignment system of this invention requires few parts, requires relatively easy assembly and does not require machining of the core barrel to accommodate final installation of the core shroud assembly. Furthermore, the alignment system of this invention facilitates easy removal of the core shroud should there ever be a future need.
[0046] The welding of the jacking blocks ( 94 ) and the alignment posts ( 100 ) to the core shroud top plate ( 90 ) is completed during core shroud assembly, not after the core shroud assembly is installed in the lower internals core barrel ( 32 ). Therefore, a significant savings in manufacturing process time will be realized since final positioning of the core shroud top plate ( 90 ) would be made by adjusting the jacking studs ( 96 ) as compared to the process of installing alignment plates described in the Background of the Invention Section hereof. Furthermore, should there be a need to remove the core shroud subsequent to reactor operation, the time required to loosen the studs in the core shroud jacking block assemblies ( 98 ) would be neglible when compared to that which would be required for the removal of the alignment plates described in the a foresighted application.
[0047] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalence thereof. | An alignment system that employs jacking block assemblies and alignment posts around the periphery of the top plate of a nuclear reactor lower internals core shroud to align an upper core plate with the lower internals and the core shroud with the core barrel. The distal ends of the alignment posts are chamfered and are closely received within notches machined in the upper core plate at spaced locations around the outer circumference of the upper core plate. The jacking block assemblies are used to center the core shroud in the core barrel and the alignment posts assure the proper orientation of the upper core plate. The alignment posts may alternately be formed in the upper core plate and the notches may be formed in top plate. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates generally to kits for complex drug regimens and methods of providing complex drug regimen items, such as methods and kits for fertility treatment regimens.
[0002] Fertility enhancement treatment requires the self-administration of a variety of drugs in a prescribed manner, order and dosage according to a specified schedule. Mistakes in the manner, order and/or dosage of fertility drugs may result in a reduced efficacy of the treatment.
[0003] More significantly, the psychological stress level of the woman undergoing fertility enhancement treatment can affect the outcome of the treatment. Higher levels of psychological stress have been linked to reduced positive outcomes. See, e.g., “DeStress for (Fertility) Success,” HealthScoutNews Jun. 29, 2001; “What Is the Stress/Infertility Connection?”, an online chat dated Jun. 2, 2003 and viewable at http://www.resolve.org/main/national/bboard/chat030602.jsp.
[0004] Koestermann et al. U.S. Patent Application Publ. No. 2003/0211627 describes a method and apparatus for managing a fertility kit. The patent application describes a box with compartments for storing medications and ancillary devices. A doctor's prescription, orders and instructions may be placed on the inside of the box's lid.
[0005] One drawback of this and other prior art complex drug regimen kits is their failure to adequately and positively identify the drugs and ancillary devices to be used in the regimen. For example, the order, dosage and timing of the drugs to be taken during fertility treatments can be difficult to follow. While the fertility kit described in the Koestermann et al. patent application provides a prescription, orders or instructions, the kit does not sufficiently tie drug names or other identification information to the corresponding drugs, nor does it tie ancillary devices, such as syringes, to the drugs to which they correspond. Psychological stress from uncertainty about which drugs and/or drug devices in the Koestermann fertility kit to use at a particular point in the treatment regimen, as well as actual treatment errors from choosing the wrong drug or device, can lead to reduced treatment efficacy.
[0006] Another drawback of earlier complex drug regimen kits is their relative inadaptability to changes in the drug regimen, such as changes to the drug contents, container sizes, etc. For example, the Koestermann et al. patent application describes the alteration of drug compartment sizes by cutting foam rubber material to accept the drugs and ancillary devices to be stored in them. This approach to constructing the kit is unduly inflexible and cumbersome.
SUMMARY OF THE INVENTION
[0007] The invention provides a complex drug regimen kit and method for providing drugs for a complex drug regimen that is easier to make and use. One aspect of the invention provides a method of providing items required for a complex drug regimen. In a preferred embodiment, the method includes the steps of disposing a plurality of different drugs in corresponding drug compartments within a container and providing drug identification information visually associated with each drug compartment containing a drug. The method may also include the step of labeling the drug compartments with labels to identify drugs to be taken together. In embodiments in which at least two of the drugs are intended to be used together, the disposing step may include the step of associating the at least two drugs with the same label.
[0008] The method may also include the step of altering a drug compartment size prior to completion of the disposing step, such as by adding or removing a wall portion of a compartment from the container or by adding or removing a false bottom to the drug compartment.
[0009] In some embodiments the disposing step may include the step of disposing a drug delivery tool with a drug in a compartment. The invention may also include the step of arranging the drug compartments in a drug compartment arrangement following an intended order of use, and the step of providing drug identification information may include the step of providing drug identification information arranged in an arrangement substantially similar to the drug compartment arrangement. The step of providing instructions may include labeling the container, such as on the container's lid.
[0010] Another aspect of the invention provides a kit for a complex drug regimen. In a preferred embodiment the kit includes: a kit container comprising a plurality of drug compartments, each drug compartment adapted to contain one or more drugs; a plurality of different drugs disposed in the drug compartments; and drug identification information visually associated with each drug compartment containing a drug. In some embodiments, the kit includes at least one label identifying drugs to be taken together. For example, if at least two of the drugs are intended to be used together, both may be associated with the label. In some embodiments the kit also includes at least one drug delivery tool disposed in a drug delivery compartment along with a drug, such as by placing the drug and its corresponding tool in an order of use within the drug compartment.
[0011] The drug compartments may be arranged in a drug compartment arrangement following an intended order of use, and the drug identification information may be arranged in an arrangement substantially similar to the drug compartment arrangement. In embodiments in which the kit container has a lid, the instructions of use may be disposed on the lid.
[0012] In some embodiments at least one drug compartment is adapted to be altered in size, such as by inserting or removing a drug compartment wall portion or false bottom. The kit may also have a biohazard container. In some embodiments, the kit container may be adapted to conceal most of the biohazard container from view when the kit container's lid is open. For example, the kit container may be adapted to conceal from view substantially all of the biohazard container except for its lid.
Incorporation by Reference
[0013] All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
[0015] FIG. 1 is a schematic drawing of a kit for a complex drug regimen according to one embodiment of the invention.
[0016] FIG. 2 is a schematic drawing of a kit for a complex drug regimen according to another embodiment of the invention.
[0017] FIG. 3 is a schematic drawing of the kit of FIG. 2 showing a cross-section taken along line A-A in FIG. 2 .
[0018] FIG. 4 is a schematic drawing of the kit of FIG. 2 loaded in a mailing container.
[0019] FIG. 5 is a schematic drawing of a kit according to another embodiment of the invention, loaded in a mailing container.
DETAILED DESCRIPTION OF THE INVENTION
[0020] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures, within the scope of these claims and their equivalents be covered thereby.
[0021] FIG. 1 shows one embodiment of the invention. A complex drug regimen kit 10 , such as a kit containing drugs for fertility treatment, contains drugs 12 , drug delivery devices 14 and other drug regimen materials arranged in drug compartments 16 formed within a box 18 or other container. The drug compartments are preferably arranged in the order in which the drugs are to be taken. Drug delivery devices or other materials needed to be used when taking a particular drug are disposed in the same compartment as the drug, such as an injectable drug and the syringe used when injecting the drug.
[0022] In this embodiment the drugs 12 and their corresponding drug delivery devices 14 are arranged in the order of their use. For example, the syringes 14 used for injectable drugs 12 are placed in front of the corresponding drugs in drug compartment 16 , as shown in FIG. 1 .
[0023] Drug identification information is also provided in the kit. In a preferred embodiment, the drug identification information is visually associated with the drugs to which it pertains. This visual association makes it easier to follow the drug regimen. For example, box 18 in FIG. 1 has a lid 20 on which the drug identification information 22 is labeled. To create the visual association between the drug identification information and the corresponding drugs, the drug identification information is arranged in an arrangement substantially similar to the drug compartment arrangement, such as in information areas 24 . This visual association reduces doubt about which drug identification information pertains to which drugs.
[0024] The drug identification information can also be used to create a common language between the patient and health care professionals. For example, one or more of the information area rectangles 24 can be labeled as “Step 1,” “Step 2,” etc., in place of or in addition to listing the drugs and devices contained in the corresponding drug compartments. When the patient is speaking with a health care professional about the drug regimen, the patient can refer to a step rather than try to identify or pronounce the drug or ancillary device name.
[0025] In addition, stress reduction materials 26 , such as pamphlets, video tapes, etc., may be provided in the kit. These stress reduction materials are part of an overall program to increase the efficacy of the drug treatment.
[0026] One particularly stressful aspect of drug regimens that include injectable drugs is the disposable of the syringes or other sharps. State and federal sharps regulations require sharps disposal in clearly marked biohazard containers. Just seeing the biohazard warning label can be a stressor; handling the container itself can be even worse. The kit of this invention therefore provides a sharps disposal biohazard container 28 that is preferably mostly concealed from view by box 18 . In the embodiment of FIG. 1 , box 18 conceals the sharps container's biohazard warning label, and sharps may be deposited in the sharps container without removing the container from box 18 . As shown in the embodiment of FIG. 1 , box 18 conceals substantially all of the biohazard container 28 except for its lid 30 .
[0027] Not all drug regimens are alike, of course. The invention therefore provides a way to customize the kit container to the contents. In the embodiment shown in FIG. 1 , one or more of the walls 32 of drug compartments 16 may be added or removed to change the shape and size of the drug compartment.
[0028] The invention also provides a way to easily mail a complex drug regimen kit. Lid 20 of box 18 has a hinged flap 34 that folds down over the front 36 of box 18 when lid 20 is closed. Fasteners 38 (such as hook and loop fasteners) are disposed on flap 34 and box front 36 to keep lid 20 closed. Box 18 may then be placed in a mailing container to send to the patient.
[0029] To facilitate mailing, box 18 preferably is sized to fit within a standard express mail box. In one embodiment, box 18 has a dimension along edge 40 of about 16.75 inches or less, a dimension along edge 42 of about 16.75 inches or less and a dimension along edge 44 of about 6.75 inches or less. In another embodiment, box 18 has a dimension of 17.25 inches or less along one side, a second dimension of about 12.25 inches or less along another side and a third dimension of about 2.875 inches or less. Other dimensions corresponding to other mailing container sizes may be used without departing from the invention, of course.
[0030] FIG. 2 shows another embodiment of a complex drug regimen kit. Kit 100 has a container 102 with a plurality of drug compartments. The drug compartments are grouped to identify drugs to be taken together, such as drugs to be taken within the same time period or as part of the single step of a complex drug regimen. In this embodiment, the drug compartments are labeled to show groupings of related drugs and drug devices. Thus, drug compartment 104 has a label 106 ; drug compartments 108 , 110 and 112 have a label 114 ; drug compartments 116 and 118 have a label 120 ; drug compartments 122 , 124 , 126 , 128 and 130 have a label 132 ; and drug compartments 134 , 136 and 138 have a label 140 . In addition to helping group the drugs and drug devices by order of use, the labels also provide a common language between the patient and a healthcare professional with regard to the drugs and drug devices by providing a convenient way of referring to the drugs and devices without having to use medical terms or chemical names.
[0031] For example, a fertility kit made and used according to this invention could be assembled as follows: Label 106 reads “Step 1,” and drug compartment 104 contains drugs and devices relating to one particular phase of a fertility treatment, ovarian control. The corresponding drug identification information is shown in Table 1, where the ovarian control medications are identified under a similar label reading “Step 1”. Note that in this embodiment the drug identification information is set forth in a format that mimics the layout of the kit's container. This drug identification information may be disposed on the inside of the container's lid, as in the FIG. 1 embodiment, or may be provided with the kit as a separate piece. If a patient has a question about the drugs taken in this phase of the treatment, she may simply refer to the “Step 1 drugs” instead of having to use their chemical names. This common and easy to use language reduces the stress associated with fertility treatments and helps increase the likelihood of a positive treatment outcome. Use of a common language also reduces the amount of time spent by patients and their health care providers during telephone calls, training sessions, etc.
TABLE 1 STEP 1 Ovarian Control As Needed: One of these medicines: Lupron Synarel STEP 2 A. Stimulation Medicines One or two of these medicines: Gonal F Gonal F Multidose Follistim Bravelle Repronex Pergonal B. Antagonist Ovarian Control If Skipped Step 1 then also one of these medicines: Antagon Cetrotide C. As Needed Viagra Suppositories Syringes & Mixing Injection Needles Needles For and Gauze Pads Stimulation Medicines for Stimulation Medicines STEP 3 As Needed: Antibiotics for male Other pills HCG Medication Syringe & Injection Mixing Needle Needle For HCG For HCG STEP 4 As Needed: Progesterone Pills Unused space As Needed: Injectable Progesterone Syringes & Injection Mixing Needles Needles For For Progesterone Progesterone ALL STEPS As Needed: Antibiotics Baby Aspirin Alcohol Pads Sharps For needle disposal only
[0032] Continuing the example, label 114 reads “Step 2,” and the drugs and devices in the corresponding drug compartments 108 , 110 and 112 contain drugs and devices related to another phase of the fertility treatment; label 120 reads “Step 3,” and the drugs and devices in corresponding drug compartments 116 and 118 relate to yet another phase of the fertility treatment; and label 132 reads “Step 4,” and the drugs and devices in corresponding drug compartments 122 , 124 , 126 , 128 and 130 relate to still another phase of the fertility treatment. Finally, label 140 reads “All Steps,” meaning the drugs and devices in drug compartments 134 , 136 and 138 may be used during any or all phases of the fertility treatment.
[0033] As in the embodiment of FIG. 1 , the kit container of this embodiment may be customized by changing the size and shape of the drug compartments, such as by adding and/or removing drug compartment walls. In addition, a false bottom may be added to any drug compartment of part of a drug compartment to raise a drug or drug device up, e.g., level with other kit contents. Thus, as shown in FIG. 3 , false bottoms 142 and 144 have been added to drug compartments 112 and 130 , respectively. In addition, inserts may be placed within a drug compartment to hold and support a drug bottle, device, etc., such as insert 146 in drug compartment 116 , as shown in FIG. 2 .
[0034] FIG. 4 shows a complex drug regimen box 200 disposed within a mailing container 202 . As shown, mailing container 202 is a standard overnight shipping box having one or more flaps 204 which, when opened, expose complex drug regimen box 200 . To facilitate removal of box 200 from mailing container 202 , one or more tabs 206 are attached to box 200 , such as by punching out portions of box lid 208 . Tabs 206 provide grips for removal of box 200 from container 202 . Alternatively, a strap may be wrapped around three sides of box 200 within mailing container 202 with the ends of the straps extending from the open end of mailing container 202 .
[0035] FIG. 5 shows a complex drug regimen tray 300 disposed in a mailing container 302 , such as a standard overnight shipping box. Once again, tabs 304 are attached to tray 300 to facilitate removal of tray 300 from mailing container 302 . | A method of providing items required for a complex drug regimen. In a preferred embodiment the method includes the steps of disposing a plurality of different drugs in corresponding drug compartments within a container; and providing drug identification information visually associated with each drug compartment containing a drug. The invention also includes a kit for a complex drug regimen. In a preferred embodiment the kit includes a kit container including a plurality of drug compartments, each drug compartment adapted to contain a drug; a plurality of different drugs disposed in the drug compartments; and drug identification information visually associated with each drug compartment containing a drug. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of Ser. No. 06/651,402, filed Sep. 17, 1984 now U.S. Pat. No. 5,108,907.
BACKGROUND OF THE INVENTION
There has been a need to find microbes in relatively large volumes of fluid, observe the activity, and identify the species. Some of the microbes that can be monitored include giardia, salmonella, escherichia coli, isochrysis, to name a few. Such fluids are, but not limited to, waste water or blood. The prior art used a system of placing a fluid sample on a glass slide and then sandwiching the sample by placing another glass slide on top of the fluid and viewing the sample with a microscope. There are a number of problems with this technique. The samples would die for lack of adequate gas exchange shortly after placement of the second slide which necessitated an immediate monitoring. The sample was also restricted to a very small volume of fluid because the top slide would displace the sample. It was virtually impossible to observe all the different types of microbe activity in the fluid. In instances where the need was to ascertain the presence or absence of a few microbes in, for example, a sample drawn from a reservoir, the very small fluid volume made direct microscopic observation useless.
There have been articles written about tracking microbes. The closest reference is a paper written by A. T. Cheung, "Quantitative Microscopy: A micro-image-analysis approach to characterize and quantitate biomotility" published in Engineering Science, Fluid Dynamics, by World Publishing Company, 1990. The article describes an optical-digital system to track the motion of microbes. The system is based on a microscope, a video camera and a computer processing system. Because that system uses a microscope to extract information describing motility, it can not monitor and track the motion of microbes in their natural state and in real-time. The limitation of that system has been mentioned in the first paragraph. Other references that relate to the tracking but are not as relevant as the paper written by A. T. Cheung are:
(1) D. Z. Anderson, D. M. Lininger, Optical tracking novelty filter, Optics Letters, Vol. 12, p. 123, 1987.
(2) Y. Li, A. Kostrzewski, D. H. Kim, Liquid crystal TV-based white light optical tracking novelty filter, Applied Optics, Vol. 28, p. 4861, 1989.
(3) N. George, S. G. Wang, D. L. Venable, Pattern recognition using the ring-wedge detector and neural-network software, SPIE, Vol. 1134, p. 96, 1989.
(4) E. C. Tam, Autonomous real-time object tracking with an adaptive joint transform correlator, Optical Engineering, Vol. 29, p. 314, 1990.
A number of articles of interest dealing with this subject are in a text entitled "The Application of Laser Light Scattering to the Study of Biological Motion" edited by J. C. Ernshaw and M. W. Steer, copyright 1990, Plenum Publishing Corp. Several articles in this text deal with laser light measurements of motility of living cells and microorgansims, with particular reference being made to the article by J. S. Ernshaw entitled "Laser Doppler Velocimetry" which describes a differential laser doppler in which one of the beams was electronically down mixed to give effective frequency shifts as low as 10 kHz, and the article by J. P. Boon entitled "Motility of Living Cells and Microorganisms" which describes the effect of stimuli on the motility of cells.
SUMMARY OF INVENTION
A primary objective of this invention is to provide an improved method and system of monitoring and identifying microbiota swimming in a fluid and to provide a sensitive method for rapidly measuring very small changes in their concentration, species composition, motility and direction of movement.
Other parameters, such as the average size of the individuals, and the growth of the total number of organisms in suspension can also be monitored. The present invention can readily be applied to phytoplankton, zooplankton, bacteria or microecosystems containing a variety of suspended microscopic plants, animals, and detritus. The invention is useful in the area of bioremediative process control, ecology, medicine, cell biology, etc..
Another advantage of this invention is to allow the characterization of a sample that will retain its vigor for a long time period as compared to the time required for such characterization.
A further advantage of this invention is to provide a method which will allow rapid in situ determination of the characteristic biota in natural and man-made bodies of water.
A still further advantage of this invention is to provide a method for continuously monitoring bioremediation systems active in fluid environments.
Additional advantages of this invention are to provide a method of monitoring the vigor of microbes in the presence of large quantities of colloidal material such as natural detritus or industrial waste products.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail in the following specification in conjunction with the accompanying drawings wherein:
FIGS. 1A-1D illustrate patterns of flagellar movement in microscopic algae which can be monitored by this invention;
FIGS. 2A and B illustrate patterns of metabolic movements of another form of microbe which can be monitored by the invention;
FIGS. 3A and B illustrate the track of an Isochrysis microbe which can be monitored by the invention;
FIG. 4 illustrates the digital record of the track of one t-Isochrysis cell which can be monitored by this invention;
FIG. 5 illustrates the track of several Isochrysis microbes on one frame which can be monitored by the invention;
FIG. 6 illustrates the tracks of several Dunaliella microbes on one frame which can be monitored by the invention;
FIG. 7 illustrates the rotation of a microbe by using dynamic diffraction patterns;
FIG. 8 is a schematic block diagram of an apparatus incorporating the invention;
FIG. 9 is a more detailed schematic diagram of the system shown in FIG. 8;
FIG. 10 is a front view of the blocker slide of FIGS. 8-9;
FIG. 11 is a side view of the blocker slide shown in FIG. 10; and
FIG. 12 is a detailed schematic diagram of the system using two laser beams for rotational measurements.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A-1D show patterns of flagellar movement of algae, FIG. 1 showing "pull" type with FIG. 1A showing the power stroke and FIG. 1B showing the return stroke; FIG. 1C shows "propeller" type locomotion and FIG. 1D showing "undulatory" type motion, with a wave (arrow) running over the flagellum. Successive positions are numbered. In FIGS. 2A and 2B, metabolic movements of the microbe Euglena are shown, FIG. 2A showing a single wave running over the cells in the direction of the arrow and FIG. 2B shows two or three waves running simultaneously. These diagrammatic sketches are from the text "Algal Physiology and Biochemistry" University of California Press, 1974, Chapter 31 by W. Nultsch entitled "Movements". These forms of motions can be used to help identify the species.
FIG. 3 illustrates the track of an Isochrysis microbe, represented by its diffraction pattern.
FIG. 4 illustrates the digital record of the track of one Isochrysis cell.
FIG. 5 illustrates an example of traces of several ISOs microbes tracked for 8 seconds. This picture is taken after the data-processing steps known as "erode" and "dilate" which improve the ratio of signal to background noise.
FIG. 6 illustrates several Dunaliella microbes to be tracked. This picture is taken after "erode".
FIG. 7 illustrates the rotation information of a microbe by using dynamic diffraction patterns.
Any microbe which moves can readily be monitored with the invention which is shown in schematic block diagram in FIG. 8. As shown therein, the system 10 of this invention comprises a laser station 12, a sample collector station 14, a picture taking station 16 and a monitoring station 18. If desired the system 10 may also include a blocking slide 20.
The invention may be broadly practiced by placing a fluid sample in the sample collection station 14. The laser station 12 has a laser for directing a laser beam at the fluid sample in the sample collector station 14 with the beam being diffracted by microbes on particulate in the sample. The picture taking station 16, has a picture taking means for taking a picture of the activity in the sample in accordance with the diffracted beam. The monitor station 18 is used for converting the picture to an analyzable record of the activity. A suitable type of monitoring may be used including those described in parent application Ser. No. 06/651,402, the details of which are incorporated herein by reference thereto. If desired the blocker slide may mask selected portions of the diffracted beam.
FIG. 9 illustrates a preferred practice of the invention. The laser station 12 has a laser such as but not limited to a helium neon laser. The laser emits a laser beam which travels to the sample collector station. The size and direction of the beam may be controlled by any suitable lens arrangement 22 and mirrors 24 between the laser station 12 and the sample collector station 14.
The sample collector station 14 has a sample collector which may be a transparent holder 26 such as glass or plastic for permitting light to pass. A fluid such as waste water, blood, etc. is placed on top of the holder. Unlike the prior art sandwich technique the top of the sample is left exposed. The sample collector is positioned so that the laser beams are emitted through the bottom of the holder and are within the volume of a fluid 28 carried in the holder 26. The sample collector or holder 26 may be housed in a suitable conventional closed system to control the environment such as temperature humidity and pressure as shown by the dotted lines around the sample collector 26 in FIG. 9.
Instead of having the sample in a closed container, the sample may flow through a transparent vessel and not remain in the vessel long enough to be deprived of respiration gases. The use of intermittent flow is a preferred way of presenting the sample to the laser beam. The flow would be stopped briefly for the period of the examination, making use of the fact that the method allows this examination to be done very rapidly. Then the flow would be restarted and stopped again after an appropriate time. The sample stream could move continuously through the sample volume. Unidirectional flow could be compensated during the analysis of frames from the camera.
After the beams pass through the sample collector, the beams travel through the blocker slide 20. Mirror 30 and lens 32 may be used to direct the diffracted beam to slide 20. The front view of the blocker slide 20 can be seen in FIG. 10 and FIG. 11. The blocker slide 20 is made from any transparent material, such as, but not limited to, glass or plastic. The function of the blocker slide 20 is only to block the central portion of laser beam (undiffracted laser beam) and has no influence on the diffracted laser beam. The center of the slide 20 has an opaque circle or dot 34 for blocking out the laser beams. The size of the opaque circle 34 controls the amount of beams passing through the slide 20. The bigger the circle the less the annular area of the beams that pass through. As shown in FIGS. 10-11 slide 20 may be detachably mounted against metal frame 36 by means of a retainer arm 38. Frame 36 in turn is attached to a base 40. Thus slides with different size opaque circles may readily replace one another.
Once the beams pass through the blocker station, the beams travel to the picture taking station 16. The picture taking station 16 has a camera 42. The camera can be, but is not limited to being, a video camera. The camera takes a picture of the activity in the sample in accordance with the diffracted laser light.
The data from the camera 42 is transmitted to the monitoring station 18. The monitoring station converts the picture to an analyzable record. The monitoring station can utilize various techniques depending on the needs of the user. One means can consist of a VCR 44 which can store the data on tape for a permanent record. In addition, a television 46 may be associated with the VCR 44 for an on line viewing of the microbiota. Any other suitable monitor could be used in place of a television for viewing.
Monitor station 18 may additionally or alternatively include a frame grabber 48, a computer 50 and a monitor 52. The frame grabber would convert the data and transmit it to the computer. The microbiota can be viewed on the monitor. Measurements can be taken and computed from the computer including size, velocity, etc.
This invention can also use a digital method to track the body rotation of a microbe via its dynamic diffraction patterns. Diffraction is another way to identify different microbe species. Every species has a different diffraction pattern. Tracking rotation of a microbe is much more difficult than tracking its position. In the position tracking, frames contained motion signals can be overlapped to form a final frame. When the tracking is finished, all the useful data is inside this final frame, can be processed later by a computer. However, in order to track rotation of a microbe in real time, data in the first frame must be taken out before the second frame comes in, and the data in the second frame must be extracted out before the third frame arrives, and so forth. Therefore, a system with a capability of parallel processing is required. (See FIG. 12)
FIG. 12 is a modified system of FIG. 9 using two or more sets of laser beams. The modification includes a laser beam splitter 25 which splits the laser beam causing two sets of beams to travel through the sample 28. The second laser beam travels through similar components designated by the suffix "A". The laser beam can also travel through a filter 21. Typically, each frame of the frame grabber 48 contains 512×512 pixels. The on board memory of frame grabber 48 can only contain four such frames. If more than four frames are to be tracked, the data must be extracted and stored into a memory on a host computer. In order to track the rotation of a microbe, the first task here is how to reduce 512×512 digital numbers into a few numbers, but these numbers should contain enough information about rotation of a microbe, then it is very fast to transfer this data from the frame grabber to a computer.
As shown in FIG. 7, a semicircle is drawn. In this semicircle, 19 points are chosen equally-spacedly, the angle difference between any two points is 10°. As can be seen from FIG. 7, when diffraction patterns rotate, the "intensity" distribution along with semicircle is also rearranged, which reserves the important and useful information about rotation of a microbe. Thus, 512×512=262,144 numbers are heavily compressed into only 19 numbers. Transferring 19 numbers from frame grabber into a host computer will be much faster. In the video world, the "real-time" means 30 frames per second. This system has the capability of further approaching the destination of "real-time". Also more data can be sampled along this semicircle to improve the sensitivity of the system.
In a practical application of the invention, system 10 would be installed in a civic sewage disposal or waste water treatment plant. Samples of waste water would be monitored continuously and the information displayed in real time in the plant control room. Because of the increased life span of the microbes in the sample with the invention, it would not be necessary for the inspector to immediately view the sample. Additionally, because the invention produces a permanent analyzable record, the inspector can view and analyze the sample at the most convenient time. In addition, because the sample fluid is in a condition which more accurately reflects the condition of the fluid in its true environment, e.g. no top plate distorts gaseous exchange between the sample and the environment, what is being monitored is a reliable indication of actual conditions. The inspector would compare the sample being monitored with a standard which is representative of acceptable activities. If there is too great a deviation from the standard, the inspector would know that a problem was developing.
The sample techniques as described with waste water could be used for other fluids such as blood, beverages, and industrial process fluids such as those found in fermentation and bioremediation systems. In the inverse of the cases previously discussed, miniature versions of the equipment, which might, for example, be built inexpensively from semiconductor laser diodes, could be installed in fluid flow systems such as domestic drinking water lines, connected to alarms which would warn of unusually high bacteria levels.
Table 1 shows many different measurements of a diluted culture of Isochrysis as illustrated in FIG. 5. There were 7 microbes tracked. The sample time was 4 seconds.
Table 2 shows many different measurements of a diluted culture of Dunaliella as illustrated in FIG. 6. There were 3 microbes tracked. The sample time was 5 seconds.
Table 3 shows digital from the dynamic diffraction patterns from a Dunaliella cell which were taken as examples. The dynamic diffraction patterns associated with a given species can be continuously observed while tracking. If necessary an independent focussed laser beam can be used for this purpose. These patterns contain information about size, shape flagellation and motility and are unique to each specie and may be presented in analog or digital form.
Table 4 shows the results of tracking of microbes in sewage water. The microbes in an "oxidation ditch" in a sewage farm are composed of many different species. It is important for the operator of a plant to be able to see images (the dynamic diffraction patterns) which give confidence that all the normal members of the team are present and active.
TABLE 1__________________________________________________________________________TRACKING MOTION OF MICROBES__________________________________________________________________________Test Sample: Diluted Culture of ISO (2).Sample Time in Second: 4NumberDX DY DD AV A0 A1 A2 A3 A4__________________________________________________________________________1 70 124 143.19 36.93 -63.95 6.129 -0.0537 0.00000 0.00002 50 74 89.78 24.14 13.11 1.178 0.0000 0.00000 0.00003 11 42 44.47 6.83 -14.33 1.000 0.0000 0.00000 0.00004 54 187 195.00 70.98 6154.70 -231.539 2.8603 -0.01157 0.00795 148 66 162.35 39.30 14.47 0.492 0.0000 0.00000 0.00006 31 54 62.89 22.72 81871.27 -2042.292 16.9699 -0.04695 0.00007 183 23 184.79 65.82 5.49 0.127 0.0000 0.00000 0.0000__________________________________________________________________________RD D0 T0 D1 T1 D2 T2 D3 T3__________________________________________________________________________51.587.800 0.000 11.031 -45.000 14.062 -56.310 7.800 0.00057.927.800 0.000 7.800 0.000 11.031 45.000 7.800 0.00020.007.800 0.000 7.800 0.000 11.700 0.000 0.000 0.000454.19 17.441 63.435 8.721 26.565 11.700 0.000 11.031 45.00013.77 11.700 0.000 14.062 33.690 21.002 21.801 24.666 18.435109.73 19.500 0.000 11.031 45.000 8.721 26.565 7.800 0.00010.45 11.700 0.000 24.666 18.435 68.111 13.241 27.300 0.000__________________________________________________________________________D4 T4 D5 T5 D6 T6 D7 T7 D8__________________________________________________________________________11.031 -45.000 11.700 0.000 14.062 -56.310 7.800 0.000 14.06214.062 56.310 8.721 26.565 5.515 45.000 11.031 45.000 8.721 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.00011.700 0.000 7.800 0.000 11.700 0.000 11.700 0.000 84.00914.062 33.690 8.721 26.565 14.062 33.690 17.441 26.565 14.062 8.721 -276.565 19.500 -36.870 7.800 0.000 7.800 0.000 0.00011.700 0.000 42.004 -21.801 11.031 0.000 66.757 0.000 0.000__________________________________________________________________________T8 D9 T9 D10 T10 D11 T11 D12 T12__________________________________________________________________________-56.310 12.333 -71.565 19.500 -36.870 16.546 -45.000 0.000 0.00026,565 14.062 56.310 0.000 0.000 0.000 0.000 0.000 0.0000.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.00068.199 47.446 80.538 11.700 0.000 24.666 71.565 8.721 26.56533.690 17.441 26.565 0.000 0.000 0.000 0.000 0.000 0.0000.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.0000.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000__________________________________________________________________________ Notes: Number represents number of microbes to be tracked. DX,DY maximum position change in X and Y direction (in micron). DD maximum linear position change (in micron). AV average velocity during sample period (micron/sec). A0 to A4 zero to forth order coefficient of motion trace equation. RD mean error of the least square curve fitting. D0 to D12 moving distance at each subsection during ST (in micron). T0 to D12 moving direction (arctan) of each subsection (in angle).
TABLE 2__________________________________________________________________________TRACKING MOTION OF MICROBES__________________________________________________________________________Test Sample: Dilute Culture of Dunaliella (1).Sample Time in Second: 5NumberDX DY DD AV A0 A1 A2 A3 A4__________________________________________________________________________1 206 97 228.54 50.31 57.20 0.536 -0.0004 0.00000 0.00002 109 132 171.78 33.46 -46.32 1.119 0.0000 0.00000 0.00003 202 136 244.46 52.13 49.13 -1.732 0.0185 0.00000 0.0000__________________________________________________________________________RD D0 T0 D1 T1 D2 T2 D3 T3__________________________________________________________________________100.36 11.700 0.000 11.700 0.000 11.031 45.000 11.700 0.00034.83 22.741 59.036 16.546 45.000 19.500 53.130 22.741 59.03648.88 23.400 0.000 27.300 0.000 36.999 18.435 19.500 36.870__________________________________________________________________________D4 T4 D5 T5 D6 T6 D7 T7 D8__________________________________________________________________________11.031 45.000 17.441 26.565 14.062 33.690 57.583 28.301 19.88622.062 45.000 16.546 45.000 14.062 33.690 16.546 45.000 16.54619.500 36.870 14.062 56.310 27.577 45.000 33.549 54.462 27.577__________________________________________________________________________T8 D9 T9 D10 T10 D11 T11 D12 T12__________________________________________________________________________-11.310 15.600 0.000 19.500 0.000 27.577 45.000 11.031 45.00045.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.00045.000 11.700 0.000 19.500 36.870 0.000 0.000 0.000 0.000__________________________________________________________________________ Notes: Number represents number of microbes to be tracked. DX,DY maximum position change in X and Y direction (in micron). DD maximum linear position change (in micron). AV average velocity during sample period (micron/sec). A0 to A4 zero to forth order coefficient of motion trace equation. RD mean error of the least square curve fitting. D0 to D12 moving distance at each subsection during ST (in micron). T0 to T12 moving direction (arctan) of each subsection (in angle).
TABLE 3__________________________________________________________________________Tracking Rotation of a Microbe from its Dynamic Diffraction__________________________________________________________________________PatternTested Microbe: Dunaliella TeriolectaTested Number: 2Total Sample Time: 5 sec.NumberD-A V-A A-AC Number D-A V-A A-AC__________________________________________________________________________ 1 150 0.00 0.00 31 160 0.00 0.00 2 200 600.00 0.00 32 250 1080.00 12960.00 3 260 720.00 1440.00 33 280 360.00 -8640.00 4 290 360.00 -4320.00 34 310 360.00 0.00 5 290 0.00 -4320.00 35 300 -120.00 -2880.00 6 340 600.00 7200.00 36 310 120.00 0.00 7 340 0.00 -7200.00 37 340 360.00 2880.00 8 50 840.00 10080.00 38 350 120.00 -2880.00 9 80 360.00 -5760.00 39 20 360.00 2880.0010 100 240.00 -1440.00 40 100 960.00 7200.0011 120 240.00 0.00 41 130 360.00 -7200.0012 130 120.00 -1440.00 42 160 360.00 0.0013 150 240.00 1440.00 43 250 1080.00 8640.0014 170 240.00 0.00 44 290 480.00 -7200.0015 200 360.00 1440.00 45 310 240.00 -2880.0016 270 840.00 5760.00 46 340 360.00 1440.0017 290 240.00 -7200.00 47 0 240.00 -1440.0018 320 360.00 1440.00 48 20 240.00 0.0019 330 120.00 -2880.00 49 60 480.00 2880.0020 310 -240.00 1440.00 50 110 600.00 1440.0021 270 -480.00 2880.00 51 120 120.00 -1576.0022 290 240.00 -2880.00 52 120 0.00 -1440.0023 300 120.00 -1440.00 53 160 480.00 5760.0024 340 480.00 4320.00 54 170 120.00 -4320.0025 0 240.00 -2880.00 55 260 1080.00 11520.0026 100 1200.00 11520.00 56 270 120.00 -11570.0027 110 120.00 -12960.00 57 310 480.00 4320.0028 120 120.00 0.00 58 310 0.00 -5760.0029 160 480.00 4320.00 59 310 0.00 0.0030 160 0.00 -5760.00 60 350 480.00 5760.00__________________________________________________________________________Total rotation (clockwise): -0.19 (turns - -70 (degrees)(counter-clockwise): 4.75 (turns) - 1710 (degrees)Net rotation during sample time: 4.56 (turns) - 1640 (degrees)Average angle velocity (clockwise): -84.00 (degrees/sec.)(counter-clockwise): 418.78 (degrees/sec.)Net average angle velocity: 333.56 (degrees/sec.)Motion Characteristic: rotation in counter-clockwise direction with a fewwobble.__________________________________________________________________________
TABLE 4__________________________________________________________________________TRACKING MOTION OF MICROBES__________________________________________________________________________Test Sample: Sewage water from Lewes wastewater treatment plant (4).Sample Time in Second: 5NumberDX DY DD AV A0 A1 A2 A3 A4__________________________________________________________________________1 58 39 70.31 37.98 -250.98 8.550 -0.0499 0.00000 0.00002 11 19 22.74 7.53 160.40 -0.439 0.0000 0.00000 0.00003 54 187 195.00 45.79 -4309.79 115.079 -0.9478 0.00234 -0.00184 70 97 120.14 30.70 100.50 -1.417 0.0000 0.00000 0.00005 11 35 37.00 9.92 57.46 0.550 0.0000 0.00000 0.00006 23 152 153.89 39.88 3636.08 -86.217 0.5135 -0.55697 0.00007 58 195 203.59 42.28 21172.25 -2258.426 89.5645 -1.56458 0.0102__________________________________________________________________________RD D0 T0 D1 T1 D2 T2 D3 T3__________________________________________________________________________ 158.997.800 0.000 7.800 0.000 7.800 0.000 7.800 0.000 29.517.800 0.000 7.800 0.000 5.514 -45.000 8.72 63.4358277.41 42.003 68.199 8.720 26.565 11.029 -45.000 8.720 26.565 97.90 14.063 -33.690 14.063 - 33.690 11.029 -45.000 7.800 0.000 98.707.800 0.000 8.720 63.435 8.720 -26.565 5.514 56.0001762.22 14.063 -56.310 14.063 56.310 11.029 -45.000 17.440 63.4354274.60 22.740 59.036 24.972 51.340 22.741 59.036 21.002 68.199__________________________________________________________________________D4 T4 D5 T5 D6 T6 D7 T7 D8__________________________________________________________________________ 5.514 45.000 7.800 0.000 8.720 -26.565 14.063 33.690 8.720 7.800 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.00022.062 -45.000 15.600 0.000 11.029 -45.000 11.029 45.000 11.70017.441 -63.435 11.029 -45.000 8.720 -26.565 17.441 -63.435 8.720 5.515 45.000 7.800 0.000 5.515 45.000 0.000 0.000 0.00011.7700 0.000 8.720 -26.565 11.029 45.000 19.886 78.690 16.08028.392 74.055 11.700 0.000 11.7700 0.000 28.392 -74.055 19.886__________________________________________________________________________T8 D9 T9 D10 T10 D11 T11 D12 T12__________________________________________________________________________-26.5657.800 0.000 8.720 -26.565 8.720 63.435 36.793 -57.9950.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.0000.000 11.700 0.000 21.002 -68.199 12.332 71.565 21.002 -68.19926.565 11.029 -45.000 11.029 45.000 15.600 0.000 5.515 45.0000.0000.000 0.000 0.000 0.000 0.000 0.000 0.000 0.00075.964 21.002 68.199 19.500 0.000 8.720 0.000 26.161 0.000-78.690 19.886 78.690 0.000 0.000 0.000 0.000 0.000 0.000__________________________________________________________________________ Notes: Number represents number of microbes to be tracked. DX,DY maximum position change in X and Y direction (in micron). DD maximum linear position change (in micron). AV average velocity during sample period (micron/sec). A0 to A4 zero to forth order coefficient of motion trace equation. RD mean error of the least square curve fitting. D0 to T12 moving distance at each subsection during ST (in micron). T0 to T12 moving direction (arctan) of each subsection (in angle). | An improved method and system of monitoring and identifying microbiota swimming in a fluid or moving across surfaces in a fluid provides a sensitive method for rapidly measuring very small changes in activity, and detecting and identifying individual microbes in relatively large volumes of fluid, even in the presence of detritus. The system comprises a laser station, a sample collector station, a picture taking station and a monitoring station. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of ophthalmics, more particularly to ophthalmic devices, and still more particularly to ophthalmic devices known as intraocular lenses (IOLs).
2. Background Discussion
At the onset it may be helpful to the understanding of the present invention to define the term "phakic" as it relates to human eyes. The term "phakic" is applied to an eye in which the natural ocular lens is still present. This is in contrast to an aphakic eye from which the natural ocular lens has--for any reason--been removed. A phakic eye is considered a dynamic or active eye because the living natural lens is subject to change over time, while an aphakic eye is considered a static eye because the natural lens has been removed.
Vision in an eye is enabled by light from a viewed image being-refracted to the retina by the cornea and the natural lens (and/or any implanted intraocular lens) located posterior of the cornea.
One relatively common ocular problem is impaired or complete loss of vision due to the natural ocular lens becoming cloudy or opaque--a condition known as cataract. The formation of cataracts is typically associated with natural bodily aging, and most individuals over the age of about 60 years suffer from cataracts at least to some extent.
Cataracts cannot currently be cured, reversed, or even significantly arrested. Accordingly, the corrective action involves surgically removing the natural lens when the lens becomes so cloudy that vision is greatly impaired, the result being that a phakic eye becomes an aphakic eye.
After a defective natural lens has been surgically removed, the current vision-restoring practice (since about the 1940's) is to implant in the aphakic eye an artificial refractive lens called an intraocular lens (IOL) having an optic and optic fixation means. Previously, thick, heavy, high diopter spectacles were prescribed for aphakic eyes. Such spectacles however were and still are generally disliked by most patients for their weight and appearance.
Implantable IOLs were initially constructed from rigid polymethyl methacrylate (PMMA), a hard, biocompatable plastic material. More recently, IOLs have been constructed from a soft, elastically deformable, silicone or acrylate material that enables insertion of the IOLs through small ocular incisions.
In addition to the implanting of IOLs in aphakic eyes to restore vision after removal of the natural lens, considerable interest has recently arisen in implanting IOLs in phakic eyes to correct myopia, hyperopia, presbyopia or astigmatism problems associated with non-cataract natural lenses. This implanting of corrective IOLs in phakic eyes is an often-attractive alternative to the wearing of corrective spectacles or contact lenses, which limit certain activities and even certain professions, or having performed such surgical procedures on the cornea as radial keratomy (RK) or photo-radial keratectomy (PRK), which may not be desired by many individuals for various reasons. The implanting of refractive IOLs in phakic eyes to correct vision problems is considered to constitute one of the remaining frontiers of vision correction.
In an aphakic eye, a replacement IOL is now typically implanted in the posterior chamber of the eye from which the natural lens has been removed. In contrast, a corrective IOL for a phakic eye is most desirably implanted in the anterior chamber of the eye, forwardly of the intact natural lens in the posterior chamber of the eye. The former is called a posterior chamber IOL and the latter is called an anterior chamber IOL, and there are significant construction differences between the two types of IOLs.
With regard to anterior chamber IOLs, there has been renewed interest in IOLs constructed for fixation to the iris (some of the earliest IOLs were iris fixated, anterior chamber IOLs). By fixing the optic supporting structure to the iris itself, contact with the sensitive filtration angle of the eye is avoided.
Iris fixated IOLs are disclosed in U.S. Pat. Nos. 4,215,440 and 5,192,319 to Jan Worst. Both of such patents disclose IOLs employing one or more optic fixation members formed having a pair of pincer arms which, acting together, pinch an anterior surface region of the iris. This pinching action detachably attaches the IOL to the iris so that the IOL optic is ideally fixated in the region of the iris opening (i.e., the pupil of the eye).
However, the present inventor considers that improvements to the iris fixated IOL designs disclosed in the two above-cited Worst patents are desirable and it is a principal objective of the present invention to provide such improvements, particularly in the areas of improving optic centration and enabling small incision implanting.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an iris fixated intraocular lens which comprises an optic having an optical axis and anterior and posterior sides and at least two fixation members, and which may have an overall diameter of between about 7.5 mm and about 10 mm. Each of the fixation members have a proximal end region and a distal end region, the proximal end region comprising a flexible strand, preferably, a single flexible strand, fixed to an edge region of the optic so as to extend generally tangentially outwardly therefrom. The distal end region is formed into a loop having defined therein at least one narrow iris pincher gap.
In a preferred embodiment of the invention, the at least one pincher gap is located on a line generally perpendicular to the optical axis, but may alternatively be formed at an angle to the perpendicular line.
It is preferred that the at least two fixation members include first and second fixation members that are substantially identical to one another and are attached to the optic on opposite sides of the optical axis. The first and second fixation members are constructed separately from the optic, the intraocular lens being thereby a three-piece intraocular lens.
It is further preferred that the optic is constructed from an elastically deformable material, which may be a silicone material or an acrylic material. Also, the at least two fixation members lie in an at least substantially common plane located posterior of the optic.
The distal end loop of each of the at least two fixation members may be elongated into a curved shape, and in some embodiments of the invention, each of the distal end loop includes means dividing the loops into first and second segments; in which case, a first pincer gap is defined in the first loop segment and a second pincer gap is defined in the second loop segment. Preferably, the loop dividing means lies generally perpendicular to the optical axis of the optic.
The at least one pincer gap preferably has a width of between about 0.05 mm and about 0.25 mm, and preferably has a length between about 0.2 mm and about 0.5 mm. The pincer gap in the distal end loop of each of the first and second fixation members may be located in a region of the loop closest to said optical axis, or in a region of the loop furthest from said optical axis. In either case, the pincer gaps are spaced a preferred distance, D, between about 8.0 mm and about 9.0 mm, away from the optical axis of the optic.
Because the fixation members are constructed as a flexible strand and the optic is constructed from an elastically deformable material, the resulting three piece iris fixated IOL of the invention can be folded, rolled or otherwise deformed for insertion through a small, sutureless incision in the eye, as is highly desirable for such reasons as minimal patient trauma and the reduced possibility of surgical complications. Also importantly, the flexible strand fixation members enable accurate centration of the associated optic in the patient's eye upon fixation of the IOL to the iris.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more readily understood by a consideration of the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a vertical cross sectional drawing of forward regions of a representative human eye, showing the cornea, iris and natural lens and showing an iris fixated intraocular lens (IOL) of the present invention implanted in the anterior chamber of the eye and fixed to the anterior surface of the iris;
FIG. 2 is a front view of one embodiment of a three piece iris fixated IOL of the present invention, showing the optic and an opposing pair of optic support or fixation members (haptics), each terminating in an elongated fixation loop having a narrow pincer gap for enabling detachable attachment of the IOL to the anterior surface of a patient's iris, the pincer gaps being shown directly facing the optic;
FIG. 3 is a side view of the IOL of FIG. 2, showing forward vaulting of the optic relative to the fixation loops;
FIG. 4 is a partial front view of a variation fixation loop corresponding to the fixation loops shown in FIG. 2, showing a spaced apart pair of iris pincer gaps defined in the elongated vertically-divided fixation loop, both of such gaps shown directly facing the optic;
FIG. 5 is a front view of a variation three piece iris fixated IOL of the present invention, showing the optic and an opposing pair of haptics, each such haptic shown curving closely around the optic and terminating in an elongated fixation loop having a narrow, perpendicular pincer gap for enabling detachable attachment of the IOL to a patient's iris, the pincer gaps being shown facing away from the optic;
FIG. 6 is a side view of the IOL of FIG. 5, showing forward vaulting of the optic relative to the fixation loops;
FIG. 7 is a partial front view of a variation fixation loop corresponding to the fixation loops shown in FIG. 5, showing a spaced apart pair of iris pincer gaps defined in the elongated vertically-divided fixation loop, both of such gaps shown directed away from the optic;
FIG. 8 is a drawing depicting the manner in which a representative right angle pincer gap, such as those shown in FIGS. 2, 4, 5 and 7, is operative for pinching an anterior surface region of an iris in a manner detachably attaching the associated fixation loop and thus the associated IOL to the iris; and
FIG. 9 is a drawing depicting the manner in which a representative angled pincer gap, corresponding to the right angle pincer gaps shown in FIGS. 2, 4, 5 and 7 is used to engage the anterior surface of an iris in a manner detachably attaching the associated fixation loop and thus the associated IOL to the iris.
In the various FIGS., the same elements and features are given the same reference numbers. In the various variation embodiments, corresponding elements and features are given the same reference numbers as first set forth, followed by an "a", "b", "c", and so on, as appropriate and as will be evident in the following DESCRIPTION.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1, in vertical cross section, a forward region 10 of a representative human eye having an optical axis 11 (Axis of symmetry). Depicted in the FIG. are a cornea 12, an iris 14 and an intact, natural crystalline lens 16. A (posterior) corneal endothelium surface 18 is identified on cornea 12.
An iris fixated intraocular lens (IOL) 20, according to a preferred embodiment of the present invention, is shown implanted in an anterior chamber 22 of eye region 10 (posterior to corneal endothelium surface 18) and fixated, in a manner described below, to an anterior surface 24 of iris 14.
Identified in FIG. 1, to facilitate the understanding of the present invention, is an annular pupiliary spincter region 28 of iris 14 that surrounds and controls a pupil or pupiliary opening 30 having a diameter, D 1 , that typically no greater than about 8 mm for normal vision.
Further identified are an annular iris collarette region 32 and an annular pupiliary dilator muscle region 34 of iris 14. An annular chamber angle 36 is identified at a peripheral edge region of iris 14, as is an annular trabecular meshwork 38. An annular ciliary processes 40 is indicated at the peripheral attachment of natural lens 16.
As is further depicted in FIG. 1, iris fixated IOL 20 is fixated to iris anterior surface 24 in the general region of iris collarette 32 (the thickest region of iris 14), radially outwardly from pupillary sphincter 28.
Shown in FIGS. 2 and 3, comprising iris fixated IOL 20 are an optic 50 and a pair of opposing, similar and preferably identical, fixation members or haptics 52. Projecting sidewardly (radially) from opposite sides of a peripheral edge 56 of optic 50, and preferably formed in one piece with the optic, are similar structural haptic attachment abutments or bosses 58. Optic 50, which has respective anterior and posterior surfaces 60 and 62 (FIGS. 1 and 3), may be constructed as convex-convex (as depicted in FIG. 1), convex-concave, convex-planar, or concave-planar or concave-concave, all such and other configurations being within the scope of the present invention. Optic 50 may advantageously be provided in the diopter range between about -15 and about +15.
It is preferred that optic 50 be constructed from an elastically deformable material, such as a silicone or acrylic material, enabling the optic to be folded, rolled or otherwise deformed so that IOL 20 can be implanted through an ocular incision no larger than about 3.5 mm. It is therefore preferable that the material from which optic 50 is constructed have an index of refraction of at least about 1.46 and that the optic have a diameter, D 2 , of between about 5.5 mm and about 7.0 mm (FIG. 3) and a center thickness, t 1 , no greater than about 0.8 mm (FIG. 1).
Each of haptics 52, which are preferably constructed (as by micro-machining) from polymethyl methacrylate (PMMA), is formed having an arcuate, flexible proximal end region 70 and a generally flat, loop-shaped distal end region 72. A proximal end 74 of each haptic 52 is fixed into an associated one of bosses 58 (FIG. 2) so that haptic proximal end region 70 extends in a direction tangential to optic edge 56. Such haptic-to-optic fixation can be of any type used by IOL manufacturers for the secure attachment of haptics to soft, flexible optics.
Haptic proximal end region 70 is arcuate in plan view and arches away from optic 50 (FIG. 2). Further, proximal end region 70 is made flexible, particularly in a plane parallel to the plane of optic 50, by preferably having a width, w 1 , of about 0.25 mm and a thickness, t 2 (FIG. 3) of about 0.35 mm. Preferably portions of haptic 52 defining distal end region loop 72 have about the same thickness as set forth for haptic proximal end region 70, and may be somewhat wider, as set forth below.
The loop into which haptic distal end region 72 is formed may be of a variety of shapes. However, the end region loop is shown in FIG. 2 as being elongated into a curved shape having a length, l 1 and flattened into a width, w 2 . By way of example, with no limitation intended or implied, such loop length, l 1 , may be about 3.0 mm and such loop width, w 2 , may be about 1.0 mm.
A side region 76 of distal end region loop 72 that is closest to and directly faces optic 50 is formed defining an iris pincer gap 78 (FIG. 2) having a width, w 3 , of about 0.1 mm and a length, l 2 , of about 0.4 mm. Iris pincer gap 78 is shown oriented in a radial direction relative to a center 80 of optic 50, but may alternatively be oriented in another direction. As further, shown in FIG. 2, both iris pincer gaps 78 of the two haptics 52 are centered on a diameter, D 3 , which is preferably about 8.5 mm. Pincer gaps 78 of both haptics 52 also lie generally on a common plane 82 (FIG. 3), the haptics being arched so that optic 50 is vaulted forwardly into anterior chamber 22 (FIG. 1) with posterior surface 62 anterior of plane 82 by a distance, d 1 , that is preferably about 0.5 mm.
Overall diameter, D 4 of IOL 20 (to ends of haptics 52) is preferably between about 7.5 mm and about 10 mm so that the IOL haptics engage iris 14 at iris collarette region 32, as noted above (FIG. 1).
As a result of the flexibility of haptics 52, after one haptic has been attached to iris 14 by a pinching action (more particularly described below), optic center 80 can be easily aligned with optical axis 11 by flexing of the second haptic 52 before the second haptic is attached to the iris. Thus, centration of optic 50 on optical axis 11 of the eye is easily achieved.
Moreover, with optic 50 constructed from an elastically deformable material, IOL 20 can be implanted through a small ocular incision, as is important to minimize surgical trauma and possible complications, and reduce patient recovery time, all as compared to the surgical procedure required to implant a rigid iris fixation IOL. Further in this regard, the explanting of the flexible IOL 20, in the event explanting becomes necessary as the patient's vision changes with time, is also made easier.
From the foregoing, it will be appreciated that many variations to IOL 20 and particularly to haptics 52 which attach the IOL to iris 14 are possible and are to be considered as being covered by the present invention.
IOL VARIATION OF FIG. 4
One of such variations is shown in FIG. 4 in connection with a variation IOL 20a, which is identical for descriptive purposes to above-described IOL 20 except as otherwise particularly described below. Corresponding elements and features are given the same reference numbers set forth above followed by an "a".
As shown, a looped distal end region 72a of a haptic 52a (corresponding to haptic 52) is divided radially (relative to center 80 of optic 50) by a narrow wall 90 into respective first and second loop sectors 92 and 94. Each such sector 92 and 94 is constructed to define an iris pincer gap 78 directly facing optic 50. Thus, each haptic 52a (only a representative one of which is shown) incorporates in distal end region 72a a spaced-apart pair of iris pincer gaps 78. This described doubling of the number of iris pincer gaps 78 in haptic loops 72a may sometimes be advantageous in securely detachably fixing IOL 20a to iris 14.
IOL VARIATION OF FIGS. 5 AND 6
Another such variation is shown in FIGS. 5 and 6 in connection with a variation iris fixation IOL 20b, which is identical for descriptive purposes to above-described IOL 20 except as otherwise particularly described below. Corresponding elements and features are given the same reference numbers set forth above followed by a "b".
A principal distinction between IOL 20b and above-described IOL 20 relates to pincer gaps 78 on haptic loops 72b facing away from optic 50 instead of directly facing the optic in the case of above-described IOL 20. Because pincer gaps 78 are spaced apart the same distance, D 3 (before disclosed in connection with IOL 20), proximal regions 70b of haptics 52b curve more closely around optic 50. Haptics 52b, are generally spaced from optic edge 56 a distance, d 2 , that is at least about equal to a closest separation distance, d 3 (FIG. 1), between anterior surface 82 of natural lens 16 and posterior surface 84 of iris 14 (a distance typically of about 0.3 mm).
Since haptics 52b are otherwise similar to above-described haptics 52, this increased, C-curvature of haptics 52b may provide somewhat increased haptic flexibility. Moreover, orienting pincer gaps 78 on haptic loops 72b away from optic 50 may, in some instances, facilitate fixation of the IOL to iris 14. The vaulting of optic 50 relative to haptic loops 72b is preferably the same as disclosed above relative to IOL 20.
IOL VARIATION OF FIG. 7
FIG. 7 depicts another variation iris fixated IOL 20c, which is identical for descriptive purposes to above-described IOL 20b except as otherwise particularly described below. Previously described features and elements are given the same reference number followed by a "c".
As can be seen, IOL 20c combines the described double pincer gap features shown for IOL 20a in FIG. 4 with IOL 20b (FIGS. 5 and 6.). Thus, as shown in FIG. 7, representative haptic loop 72c is vertically divided by a narrow wall 90c into first and second loop sectors 92c and 94c, respectively. Each sector 92c and 94c has defined a pincer gap 78 that faces away from associated optic 50.
Pincer gaps 78 on both haptic loops 72c (only one such loop being shown) are spaced a distance D 3 (defined above) apart.
OPERATION OF PINCER GAPS
FIG. 8 depicts the manner in which a representative one of pincer gaps 78, on a representative haptic distal end region loop 72 pinches up a small surface segment 98 of iris tissue into the gap, thereby releasably or detachably fixing the associated haptic (e.g., haptic 52), and hence the associated IOL (e.g., IOL 20), to iris 14.
This pinching up of iris segment 98 is accomplished, for example, by deflecting haptic loop regions 100 and 102 on each side of gap 78, downwardly (direction of Arrows rows "A") into iris surface 24. When the loop regions are released, they return to their original shape, thereby trapping iris segment 98 in gap 78.
VARIATION IRIS PINCER GAP OF FIG. 9
It is to be understood that variations of the iris pincer gap may be made within the scope of the present invention and used in place of above-described pincer gap(s) 78. An example of such a variation is depicted in FIG. 9, in which a slanted iris pincer gap 78d (corresponding to above-described pincer gap 78) is depicted formed or defined in a representative haptic distal end region loop 72d (corresponding to above-described distal end region loop 72).
Pincer gap 78d is depicted in FIG. 9 as formed or defined along a line 112 that is at an angle, α, relative to a line 114 perpendicular to end region loop 72d. Preferably, slant angle, α, is between about 30 degrees and about 60 degrees, with a slant angle of about 45 degrees being most preferred.
It is evident from FIG. 9 that when end region loop 72d is pressed against iris anterior surface 24 and is pushed or advanced in the direction indicated by Arrow "B", a sharp, leading lower edge 116 at gap 78d cuts into iris 14. This causes a small sliver 118 of iris 14 to be extruded into gap 78d, to thereby detachably fixate end region loop 72d, and hence associated haptic and IOL (neither shown in FIG. 9) to iris 14.
Distal end region loop 72d can be detached from iris by merely rotating the end region loop back in the direction indicated by Arrow "B'".
Although there have been described above an iris fixated IOL, and variations thereof, in accordance with the present invention for purposes of illustrating the manner in which the present invention maybe used to advantage, it is to be understood that the invention is not limited thereto. Consequently, any and all variations and equivalent arrangements which may occur to those skilled in the applicable art are to be considered to be within the scope and spirit of the invention as set forth in the claims which are appended hereto as part of this application. | An iris fixated intraocular lens for implanting in the anterior chamber of an eye comprises an optic having an optical axis and anterior and posterior sides; and first and second fixation members, each of the fixation members having a proximal end region and a distal end region. The proximal end region of each fixation member is a single flexible strand fixed to an edge region of the optic to extend generally tangentially outwardly therefrom and the distal end region is formed into a loop having defined therein at least one narrow iris pincher gap for detachably attaching the intraocular lens to the anterior surface of the iris. The first and second fixation members are substantially identical to one another and are attached to the optic on opposite sides of the optical axis. The optic is preferably constructed from an elastically deformable plastic material, such as silicone or an acrylic, so that the resulting three-piece intraocular lens can be folded or otherwise deformed for implanting into an eye through a small, preferably sutureless, surgical incision. Variation IOLs are disclosed, such variations relating to iris pincer gaps. | 0 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates generally to apparatus and methods for logging and servicing bore holes and more particularly to an apparatus and method for logging and serving both vertical and highly deviated bore holes with logging or servicing tools run into the bore hole on the end of a string of pipe which allows the logging or servicing tools to be manipulated with respect to the string of pipe.
B. Description of the Prior Art
An important aspect of the field of drilling, completing, and servicing oil and gas wells involves the use of well logging and well servicing instruments. These instruments are commonly called tools and the operation of these tools is referred to as logging or servicing. Logging involves placing tools in the bore hole drilled in the earth for the purpose of locating or identifying subterranean formations and extracting oil, gas, water, or other minerals. For example, some of these tools or combinations of tools are used to evaluate general lithological structure, including formation resistivity, porosity, matrix, or fluid or gas content. Measurements include acoustics, resistivity, temperature, pressure, natural radiation, induced radiation, and many others. Other tools are used for core sampling, cementing, perforating casing or tubing, and other tests.
In some instances, it is necessary that the tool be positioned in a certain relationship to the bore hole wall. For example, compensated density tools and compensated neutron tools have a pad that is extendd outwardly from the tool into contact with the bore hole wall. The pad must be in such contact in order for the tool to preform properly. Other tools, such as mandrel neutron tools, require close proximity to the bore hole wall. Core sample tools require an optimum spacing from the bore hole wall in order to achieve maximum efficiency. In other instances, centralization in the bore hole is required for operation of such tools as dip meters or sonic tools.
Several systems are used to transport tools into and out of bore holes in order to perform their specialized operations. One conventional system uses a wireline as the conveyer. The wireline includes at least one conductor for providing electric communication for the tool to the surface and the tool is lowered on the wireline by gravity into a position to log the bore hole. In many cases of deviated holes with inclinations above 55 degrees, and in some cases less depending upon hole conditions, gravity does not provide sufficient force to move the tools down the hole and wireline logging is impossible.
A system that has been developed to log highly deviated tools includes positioning a string a drill pipe near the zone of interest and pumping a wireline with an assembly of small diameter tools out the bottom end of the drill pipe and allowing the tools to fall by gravity through the zone of interest. A very high angle bore hole can be traversed by this method as long as the open hole inclination in the zone of interest is low in angle and hole conditions permit the tool to fall by gravity. The bore hole is logged by extracting the cable and pulling the tool through the zone of interest. The pump down system is of limited untility because the small sized tools are typically of lesser quality as regards to accuracy and quality of measurement than are the larger suites of tools used in conventional wireline operations. Also, the pump down system is limited to certain hole profiles and relatively short logging zones. Additionally, the tools may be lost due to sticking. A further shortcoming of the pump down system lies in the fact that gravity provides the only means for orienting the tools.
Another system for logging high angle bore holes is disclosed in Escaron U.S. Pat. No. 4,349,072, in which the tools are lwored using a drill pipe as the conveyer and pumping an extension with a wet connector down the drill pipe into electrical connection with the tools. The tools are released and moved axially into the bore hole with respect to the drill pipe. The hole is logged by pulling the tool back into the drill pipe with a wireline. In Barry, et al. U.S. Pat. No. 3,957,118, measurement-while-drilling-type logging is conducted using a wet connector and cable stored within the drill pipe. The tools are secured at the lower end of the drill pipe above the bit and tool positioning is controlled and limited by the drilling operation.
Base U.S. Pat. No. 4,062,551, Tricon U.S. Pat. No. 4,200,297, and Marshall U.S. Pat. No. 4,388,969 each disclose systems that include a side-entry sub secured in the drill string to provide communication between tools and the surface by means of a wireline. The tools are pumped down the drill pipe to a predetermined location and the tools are conveyed into and out of the well bore by adding and removing drill pipe above the side-entry sub. Initially, the above systems were used in connection with steering tools in bent sub mud motor drilling. More recently, as disclosed by the Marshall U.S. Pat. No. 4,388,969, the systems have been used in logging. Wittrisch U.S. Pat. No. 4,457,370 discloses a system similar to what is disclosed in Marshall U.S. Pat. No. 4,388,969 and Barry, et al. U.S. Pat. No. 3,957,118 or Escaron U.S. Pat. No. 4,349,072, in which the tools are secured to the bottom of the drill string and a wet connector is pumped down to the tools via a side-entry sub. Again, the tools are conveyed into and out of the well bore by adding and removing sections of drill pipe above the side-entry sub. The tools are oriented within the well bore by rotating the drill string.
In practice, especially in deviated holes with depths from 3,000 to 20,000 feet or more, rotation or other manipulation of the drill string from the surface in order to orient tools at the bottom of the drill string is impractical due to the elasticity of the drill pipe and drag on the bore hole walls. Although orientation can be achieved with some difficulty, it is extremely difficult to maintain that orientation. The difficulty in maintaining the orientation is primarily due to torque build up in the drill string during the act of rotation from the surface. Normally, after logging a few hundred feet or less, the build up of torque or torque generated by moving the drill pipe through a corkscrew profile will rotate the tool out of position. Positioning the tool becomes even more difficult once the side-entry sub has been lowered into the well bore. After the side entry sub has been lowered, the wireline extends up to the surface along the outside of the drill pipe. With the wireline in the annulus, it is preferable not to rotate the drill string because such rotation can wrap the wire line about the drill string which can result in damage to the wire line or prevent its emergency extraction.
It is therefore an object of the present invention to provide an apparatus and method for logging bore holes and servicing wells that overcomes the shortcomings of the prior art. More particularly it is an object of the present invention to provide an apparatus and method for logging bore hole formations and servicing wells that is applicable from vertical through high deviations that are not accessible with standard wireline techniques. It is a further object of the present invention to provide a conveyer for positioning tools in a well bore that allow for rotation or other manipulation of the tools to selected orientations without rotating or manipulating the conveyer at the surface. It is yet a further object of the present invention to provide an improved system for performing downhole operations.
SUMMARY OF THE INVENTION
Briefly stated, the foregoing and other objects are accomplished by the apparatus and method of the present invention. The invention includes a conveyor that is adapted for movement into and out of the well bore. An incremental rotating device is attached to the conveyor and selected control devices are connected to the incremental rotating device. Logging or servicing tools are in turn attached to and operated by the control devices. The conveyor may be moved back and forth within the bore hole between the surface and the zone of interest to perform logging and servicing operations. The conveyor is adapted to provide fluid pressure to the incremental rotating device to cause the incremental rotating device to rotate through a predetermined radial angle. The rotation of the incremental rotation device causes the control device to manipulate or otherwise operate the logging or servicing tools. The conveyor is preferably a string of drill pipe, but it may also be conduit, rods, tubing, slickline, or electric wireline. The fluid pressure is preferably provided by surface pumps via the drill pipe conveyor, but it may also be provided by a hose or conduit when the conveyor is a wireline, slickline or rod, or by a downhole pump.
In one aspect of the invention, the control device transmits rotation from the incremental rotation device directly to the logging tool. The incremental rotation device is affixed to the conveyor and sequential application of hydraulic or fluid pressure to the incremental rotation device causes the incremental rotating device, through the control device, to rotate the tools to a selected radial attitude. In another aspect of the invention, the control device includes means for converting rotational movement into translational movement which is adapted ot extend or project tool elements outwardly to perform logging or servicing operations. The control device is also adapted for translating rotational movement into translational movement to operate various downhole tools. In yet another aspect of the invention, a control device is provided to release tools into the wellbore.
The rotating device includes a body connectable to the string and a mandrel rotatably mounted in the body and connectable to the tool assembly. A drive piston is axially slidingly disposed between the body and the mandrel and the device includes means for transmitting rotational forces to the mandrel in response to axial movement of the drive piston. Broadly, the rotational force transmitting means includes a ratchet sleeve nonrotatably engagaeable with the mandrel. The ratchet sleeve has a slot formed therein and the slot has a helical portion. A drive pin is axially movably carried with the drive piston and is in engagement with the slot. Thus, axial movement of the drive piston is translated into rotational movement of the mandrel through the cooperation of the pin and slot. Preferably, the rotating device includes means for preventing rotation of the mandrel with respect to the body when the drive piston is in either of its extreme positions with respect to the body and mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a deviated well bore showing the environment of the present invention.
FIGS. 2A-C are sectional views of the rotating device of the present invention.
FIG. 3 is a partial sectional view of the rotating device of the present invention showing the drive piston in its fully inward position.
FIG. 4 is a perspective view showing details of a portion of the rotating device of the present invention.
FIGS. 5A-B are sectional views showing an alternative embodiment of the present invention that provides means for extending and retracting various tools of the tool assembly.
FIG. 6 is a sectional view of a portion of a further alternative embodiment of the present invention which provides means for retracting or extending various devices radially with respect to the tool assembly.
FIG. 7 is a view taken generally along line 7--7 of FIG. 2A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and first to FIG. 1, a drilling rig 10 is shown above a well bore 12. The lower portion of well bore 12 is deviated at a high angle away from the vertical. An elongated drill string 14 extends down into well bore 12 and has a logging tool assembly 16 attached to its lower end. Drill string 14 is made up of a plurality of end-to-end connected sections of pipe, each designated by the numeral 18.
Drill string 14 extends down through the floor 20 of rig 10 into well bore 12. A conventional rotary table and slip assembly 22 for rotating and supporting drill string 14 is shown. A power wench assembly 24 is connected to an elongated cable or wireline 26 and is suitable for paying out and reeling in the cable. Cable 26 passes over suitable sheaves 28 and 30 in rig 10 and into well bore 12 adjacent drill string 14. A side-entry sub 32 is provided in drill string 14 so that cable 26 may enter the interior of drill string 14.
Logging tool assembly includes a protective sleeve encompassing one or more downhole logging tools. In the example shown in FIG. 1, logging tool assembly 16 includes a gamma ray tool 34 for measuring the natural radioactivity of the formation. Logging tool assembly 16 also includes a compensated neutron tool 36 and a compensated density tool 38. Compensated neutron tool 36 includes a pad 37 that is adapted to be extended radially outwardly through slots in the protective sleeve to make contact with the well bore wall. Similarly, compensated density tool 38 includes a pad that is likewise adapted to be extended radially outwardly into contact with the well bore wall. Generally, the compensated neutron tool measures the hydrogen concentration in the formation, which is indicative of the amount of petroleum and water in the formation. Compensated density tool 38 measures the electron density in the formation, which is related to the true bulk density of the formation. Finally, logging tool assembly 16 includes an inductive logging device 40 which measures the resistivity of the formation.
Logging tool assembly 16 includes along the length of its protective sleeve a plurality of stabilizers 42, which are preferably rotatable with respect to assembly 16. Stabilizers 42 are included in order to keep the bodies of the various logging devices from rubbing against the bore hole wall and to provide a degree of centralization of logging tool assembly 16 and provide a bearing surface during rotation. Fluted stabilizers are shown, but well known spring stabilizers and so-called "rubbers" are suitable.
Those skilled in the art will recognize that logging tool assembly 16 may include other or alternative logging devices and that the composition of logging tool 16 as shown in FIG. 1 is for purposes of illustration only. Also, for purposes hereof, the term logging tool is used in a broad sense to include such devices as core samplers, perforating guns, and other downhole tools.
In positioning logging tool assembly 16 for performing logging operations, or other procedures in accordance with the particular type of tool being used, the tool is typically lowered to the upper portion of the zone of the well bore to be surveyed and the side-entry sub 32 is added to the drill string 14. Wireline cable 26 is then inserted through a suitable port in side-entry sub 32 and lowered or pumped down the interior of drill string 14 for electrical connection to logging tool assembly 16 by means of a latch or connector assembly (not shown). After wireline cable 26 is connected to logging tool assembly 16, additional lengths of pipe 18 are connected in end-to-end fashion above side-entry sub 32, thereby to run logging tool assembly 16 into bore hole 12 below the zone of interest. The zone of interest is then logged by removing sections of pipe 18.
As shown in FIG. 1, logging tool assembly 16 tends to lie on the low side of well bore 12. Certain of the tools of logging tool assembly 16 need to be in relatively close proximity to the walls of well bore 12 in order to operate properly. For example, pads 37 and 39 of compensated neutron tool 36 and compensated density tool 38, respectively, need to be in actual contact with the well bore wall. Pads 37 and 39 are shown in FIG. 1 displayed about 90 degrees from the low side of the hole; however, they could be oriented at virtually any other angle with respect to the low side of the hole, as for example 180 degrees or toward the high side of the hole. Centralization of logging tool assembly 16 is impractical because of the large weight of logging tool assembly at the end of drill string 14. Also, since normal continuous rotation, circulation, and reciprocation of the drill string cannot be accomplished, centralization of the lower section of drill string 14 adds to the potential of sticking, which could result in the loss of a portion of the drill string and tools. Rotation of pads 37 and 39 toward the low side of the hole by rotating drill string 14 at rotary table 22 is generally impracitcal since drill string 14 tends to twist and store tortional stresses over its length. Generally, rotation of the end of drill string 14 at rotary table 22 through a given angle results in the rotation of logging tool assembly 16 through a much smaller angle. However, as drill string 14 is pulled out of bore hole 12, the tortional stresses are relieved and logging tool assembly 16 rotates. Also, rotation of drill string 14 at rotary table 22 is generally unsatisfactory in that it cause wireline cable 26 to wrap about drill string 14. Accordingly, in the present invention, an incremental rotating apparatus 44 and control device 45 are provided for rotating logging tool assembly 16 with respect to drill string 14.
Referring now to FIGS. 2A-C, incremental rotating apparatus 44 generally includes a tubular body 46 and a tubular mandrel 48 mounted within body 46. Body 46 is connectable at its upper end to a drill string by means of an internally threaded upper member or coupling 50. The lower end of mandrel 48 is externally threaded for connection to logging tool assembly 16.
Mandrel 48 is rotatably mounted within body 46 by means of bearings 52 and 54. Mandrel 48 includes a radially outwardly extending annular shoulder 56 supported between bearings 52 and 54. A bearing sub 58 is threadedly engaged to body 46 to support lower bearing 54 and a bearing retainer 60 is threadedly engaged to bearing sub 58 to retain upper bearing 52 against shoulder 56. A seal 62 is provided for sealing between mandrel 48 and bearing sub 58 below lower bearing 54. A compensating piston 64 is disposed between mandrel 48 and bearing retainer 60 above upper bearing 52. Seals 65 and 66 are provided between mandrel 48 and compensating piston 64 and compensating piston 64 and bearing retainer 60, respectively. Seal 62 and compensating piston 64 form therebetween a lubrication chamber 67 that is filled with an oil to lubricate bearings 52 and 54. Oil may be introduced into and bled from lubrication chamber 67 through ports 68 and 69 in bearing sub 58 and bearing retainer 60, respectively. Compensating piston 64 serves to maintain the pressure within lubrication chamber 67 at ambiant pressure. At least one port 70 is formed in bearing retainer 60 to allow for communication of pressure to compensating piston 64. A plurality of ports 71 are formed in body 46 to allow for equalization of pressure within body 46.
Referring particularly to FIG. 2A, mandrel 48 is incrementarlly rotatable with respect to body 46 by means of a ratcheting system which includes an annular drive piston 72 disposed generally between a piston sleeve 74 and a guide sleeve 76. Guide sleeve 76 is positioned about mandrel 48 and is threadedly engaged at its lower end with bearing retainer 60 and at its upper end with a piston stop 77. Guide sleeve 76 includes at least one axially extending guide slot 78 and a plurality of detent apertures 79. Piston sleeve 74 is retained in body 46 between upper member 50 and piston stop 77 and provides a sealing bore for piston 72.
Piston 72 includes an upper sealing portion 80 having appropriate seals for sealing engaging piston sleeve 74 and guide sleeve 76 and a lower portion 81 which carries a plurality of drive pins 82. Drive pins 82 engage guide slot 78 in guide sleeve 76, thereby to prevent rotation of drive piston 72 with respect to guide sleeve 76 and body 46. Drive piston 72 includes a central portion 83 having a plurality of axially extending pressure compensation ports 84 therein.
Drive piston 72 is normally urged axially upwardly into contact with piston stop 77 by means of a piston return spring 86. Piston stop 77 includes a plurality of flow passages 87 which communicate fluid pressure from the interior of body 46 to drive piston 72. When the pressure on drive piston 72 is sufficient to overcome the force of piston return spring 86, drive piston 72 is driven axially downwardly within body 46 to the position shown in FIG. 3. When the pressure is reduced, piston return spring 86 drives piston 72 back to the position of FIG. 2A. The cooperation of drive pin 82 in guide slot 78 prevents piston 72 from rotating with respect to body 46.
The axial movement of drive piston 72 is transmitted to mandrel 48 through a ratchet sleeve 89, which is disposed between mandrel 48 and guide sleeve 76. Ratchet sleeve 89 includes a plurality of slots 90 which are engaged by drive pins 82. Referring particularly to FIG. 4, each slot 90 includes an axially extending first portion 92, a helically extending portion 93, and an axially extending third portion 94. As drive piston 82 moves axially from the position of FIG. 2A to the position of FIG. 3, drive pins 82 travel first through first portion 92 of slot 90, then through helical portion 93, and finally through third portion 94. Since drive pins 82 are constrained to move axially, the movement through helical portion 93 imparts rotational motion to ratchet sleeve 89. The rotational movement of ratchet sleeve 89 is normally transmitted to mandrel 48 by a plurality of serrated locking ratchets formed at the lower end of ratchet sleeve 89 which engage a plurality of ratchet pawls 98 formed on mandrel 48. Locking ratchets 96 and locking pawls 98 have complimentary axially extending engagement surfaces 97 and 99, respectively, and complimentary helical surfaces 100 and 101, respectively.
Referring again to FIG. 2A, ratchet sleeve 89 is normally urged into engagement with locking pawls 98 by a ratchet return spring 102. Ratchet return spring 102 is compressed against ratchet sleeve 89 by a ratchet spring retainer 104 threadedly engaged with the upper end of mandrel 48. The rotational movement to ratchet sleeve 89 as drive pins 82 move through helical portions 93 of slots 90 is transmitted through axial surfaces 97 and 99 of locking ratchets 96 and locking pawls 98, respectively, to mandrel 48. As drive pins 82 move axially upwardly from the position of FIG. 3 back through helical portions 93 toward the position of FIG. 2A, ratchet sleeve 89 is lifted and rotated about mandrel 48. When drive pins 82 move into the axial first portions 92 of slots 90, ratchet return spring 102 urges ratchet sleeve 89 back into engagement with locking pawls 98.
Mandrel 48 is prevented from rotating with respect to body 46 when piston 72 is in its first, outward, position, as shown in FIG. 2A and in its second, inward, position shown in FIG. 3, and during movement of piston 72 from the second position to the first position. In other words, means are provided so that mandrel 48 is rotatable with respect to body 46 only when piston 82 moves from the first position, as shown in FIG. 2A, to the second position, as shown in FIG. 3.
Referring particularly to FIG. 7, the rotation preventing means includes a plurality of detent recesses 106 formed in mandrel 48. Preferably, detent recesses 106 are defined in the spaces between locking pawls 98. Detent recesses are engaged by a plurality of detents 108 radially movably carried in detent apertures 79 of guide sleeve 76. When drive piston 82 is in its first position, shown in FIG. 2A, detents 82 are held radially inwardly in engagement with detent recesses 106 by a radially inwardly enlarged surface 109 of a locking sleeve 110. Locking sleeve 110 is disposed about guide sleeve 76 and includes a radially outwardly extending flange 111 positioned between lower portion 81 of drive piston 72 and piston return spring 86. As drive piston 72 is urged axially downwardly, surface 109 of locking sleeve 110 moves out of engagement with detents 108, thereby allowing detents 108 to move radially into an enlarged portion 113 of locking sleeve 110 when piston 72 has moved a distance equal to the length of first axial portion 92 of slot 93 of ratchet sleeve 89. As drive pins 82 traverse the helical portion 93 between axial portions 92 and 94 of slot 90, mandrel 48 is free to rotate with respect to body 46. As drive pins 82 reach axial third portion 94 of slot 90, the lower end 115 of drive piston 72 reaches a floating sleeve 116 disposed between guide sleeve 76 and locking sleeve 110 in enlarged portion 113. Continued movement of drive pins 82 in axial third portion 94 moves floating sleeve 116 axially into engagement with detents 108 to urge detents 108 radially inwardly back into engagement with detent recesses 106, as shown in FIG. 3. As piston return spring 86 urges drive piston 72 from its second position back to its first position, floating sleeve 116 remains in engagement with detents 108 until floating sleeve 116 is moved axially upwardly by the lower portion of locking sleeve 110, whereupon surface 109 again engages detents 108.
To summarize the operation of rotating apparatus 44, when it is desired to rotate logging tool assembly 16 with respect to drill string 14, the pressure of fluid within body 46 of rotating apparatus 44 is increased to drive drive piston 72 axially from its first position, as shown in FIG. 2a, toward its second position, as shown in FIG. 3. Axial movement of drive piston 72 causes movement of drive pins 82 within slot 90 of ratchet sleeve 89 and causes movement of locking sleeve 110 to release detents 108 from detent apertures 106, which allows mandrel 48 to rotate with respect to body 46. Movement of drive pins 82 through helical portion 93 of slot 90 causes mandrel 48 to rotate through an angle equal to the angular separation between first portion 92 and third portion 94 of slot 90. When drive pins 82 reach the lower end of helical portion 93 of slot 90, floating piston 116 urges detents 108 back into engagement with detent recesses 106, thereby preventing further rotation of mandrel 48. When the pressure within body 46 is relieved, piston return spring 86 urges drive piston 72 back to its first position. Thus, mandrel 48 can be rotated incrementally with respect to body 46 by successive applications of pressure.
Referring to FIGS. 2B and 2C, control device 45 includes an extension sub 118 threadedly engaged to the lower end of mandrel 48. A port sub 119 is threadedly engaged to extension sub 118 and includes a plurality of ports 120 for the circulation of fluid from the interior to the exterior of port sub 119 and for creating sufficient backpressure to operate incremental rotation device 44. Port sizes may be selected to develope sufficient pressure for rotation over a range of mud weights and flow volumes. A tubular protective sleeve 121 is threadedly engaged to port sub 121 and extends axially to protect and contain the logging tool assembly 16. A tubular connector guide 122 is supported within extension sub 118, port sub 119, and protective sleeve 121 by means of a tool hanger 123. Connector guide 123 includes a plurality of ports 124 for the flow of fluid into the annular space between protector sleeve 121 and connector guide 122 and eventually out ports 120 of port sub 119. Connector guide 122 supports at its lower end a connector 125 which establishes electrical connection with a tool 126.
In operation, tool assembly 16 is affixed at the surface to control device 45, which in turn is affixed to incremental rotating apparatus 44. The assembly thus formed is in turn affixed to the end of drill string 14, which is run into well bore 12 to a point above the zone of interest. Then side-entry sub 32 is connected to drill string 14 and wireline 26 is inserted into side-entry sub 13 and lowered or pumped through drill string 14 to establish connection with logging tool assembly 16. Then, additional stands of pipe are added to drill string 14 above side-entry sub 32 thereby to move logging tool assembly down the borehole and through the zone of interest.
In the foregoing example, tool assembly 16 is secured only in axial relationship to drill pipe 14 and can be incrementally rotated by providing a sequence of circulating mud pulses through the drill pipe and control device port sub 119. The hydraulic pressure thus produced operates incremental rotating device 44 to rotate tool assembly 16 through control device 45 to a desired position. Stabilizers 42 are preferably free to rotate around tool assembly 16 thus acting as a bearing surface for rotation of the tool. The problems with torque and cable damage can thus be eliminated and orientation of tool pads such as used with compensated density or compensated neutron tools can be accomplished to maintain a position to ensure contact with the bore hole wall without centralization. Since normal continuous rotation, circulation, and reciprocation of drill string 14 cannot be accomplished during logging, centralization of the lower section of the drill pipe becomes increasingly dangerous adding to the potential sticking and resulting loss of a portion of drill string 14 and or tool assembly 16. Downhole control of the position of the tool active pads allows much smaller stabilizers to be used, which decreases the potential of sticking and still maintains a close proximity to the well bore wall for other tools.
The device preferably includes means (not shown) for measuring the orientation of the tools so that the position of the tool in the well bore can be determined. For example, it may be desired to orient the active pad of a tool toward the low side of the hole, in which case it is necessary to establish a reference to the vertical plane. A simple gravity potentiometer is sufficient for that purpose when the hole is inclined greater than about 15° from the vertical. Some tools, such as directional tools and dip meters, have accelerometers that establish orientation.
Referring now to FIGS. 5A and 5B, there is shown an alternative control device 128 which is adapted to extend and retract an active part of a tool 130 with respect to a protective sleeve 131. Control device 128 includes a tubular housing 132 threadedly engaged with the lower end of body 46 of rotating device 44. A reversing screw housing 134 is threadedly engaged to the lower end of mandrel 48. A reversing screw 135 is housed within screw housing 134. Reversing screw 135 includes an endless helical screw thread 136 which is engaged with screw housing 34 by a reversing ball 137.
Reversing screw 135 has at its upper end a connector 139 and at its lower end a tool support 140. Tool support 140 has formed therein an axially extending guide slot 141, which is engaged by a guide pin 142 in a port sub 143 connected between housing 132 and protective sleeve 131.
Rotation of mandrel 148 with respect to body 46 causes rotation of screw housing 134 with respect to housing 132. Reversing screw 135 is restrained against rotational movement by the cooperation of guide pin 142 and guide slot 141. Accordingly, rotational movement of mandrel 48, as described above, is translated through reversing screw 135 into axial movement of screw 130. Continued rotation of mandrel 48 causes reversing screw 135 to reciprocate inwardly and outwardly. Screw housing 134 includes a plurality of fluid passages 145 which permit fluid to flow from the interior of screw housing into the annular space between screw housing 134 and housing 132 and out a plurality of ports 146 which developes rotational pressure in port sub 143.
Control device 128 is particularly adapted for use in connection with such tools as perforating or sampling guns, which are projected out of protective sleeve to operate and then retracted prior to recovery. Incremental rotation of apparatus 44 causes tool 130 to advance and then retract.
Referring now to FIG. 6, there is disclosed an alternative special control device designed generally by the numeral 150. Special control device 150 is adapted to extend and retract various appurtenances (not shown) to a tool 151. Special control device 150 includes an extension housing 152 threadedly engaged to the lower end of body 46 of rotating apparatus 44 and a reversing screw housing 153 threadedly engaged to the lower end of mandrel 48. A reversing screw 154 is mounted within screw housing 153 and includes a short endless screw thread 155 which is engaged with screw housing 153 by means of a reversing ball 156.
Special control device 150 includes a port sub 157 threadedly engaged to the lower end of housing 152. Tool 151 is retained within port sub 157 by means of a tool retainer 158. Port sub 157 includes a port 160 which receives fluid from fluid passages 161 in screw housing 153, which developes back pressure for rotation.
Reversing screw 154 includes at its upper end a connector 163 and at its lower end a shaft 165. Shaft 169 extends into tool 151 and is adapted to operate various appurtenances (not shown) to move with respect to tool 151. Rotation of mandrel 48 with respect to body 46 of rotating appaatus 44 causes screw housing 153 to rotate with respect to reversing screw 154. The rotation of screw housing 153 with respect to reversing screw 154 causes shaft 165 to reciprocate with respect to tool 151, thereby to operate the appurtenances.
Control device 150 is particularly useful in connection with performing operations such as projecting pads, calipering device, and formation testing equipment radially outwardly with respect to a tool body. Incremental rotation of apparatus 44 is transmitted through reversing screw 154 to extend and retract the devices. Additionally, control device 152 could find use in servicing predetermined formation intervals with select-fire core guns or select-fire perforating guns. For example, a core gun assembly or perforating gun assembly could be mounted to the lower end of control device 152 and control device 152 could be loaded with a ratcheting mechanism interfaced with a multiple percussion firing head on a core gun or perforating gun assembly. With each incremental rotation of rotating device 44, control device 152 will ratchet and release to operate the core gun or perforating gun assembly. Sampling or perforating in different sections of formation could be accomplished on one trip of the conveyor. A wireline would not be necessary for communication in this special application. The foregoing method would replace an existing method wherein tubing conveyed guns are detonated or fire by a pumped down bar. An alternative to the percussion firing head is an electrical firing head interfaced to a rotary contact control mechanism connected to the mandrel 48 of rotating apparatus 44 to provide electric power to a predetermined gun of the assembly during the rotational sequence.
In both types of firing heads, the pumps at the surface will be circulating fluid allowing communication by pressure monitoring at the standpipe when the tool detonations occur. With the pressure transducer mounted in the standpipe, detonation can be detected and recorded. Additional information can be transmitted through the fluid by having one or more orifices that are either restricted or opened at preselected increments of the rotational sequence showing a pressure shift at the surface. These pressure shifts can be used to indicate the status or point of firing selection in the sequence in case of problems or misfires.
A further method of use of the apparatus of the present invention involves a release mechanism operated by rotating apparatus 44. Such system requires that at least a portion of the tool assembly be projected out of a protective sleeve and at least a portion of the tool assembly be centralized in the hole. One such control device arrangement would include a clutch between the protective sleeve and mandrel 48 of incremental rotating apparatus 44 and a release mechanism between mandrel 48 and the tool assembly. The clutch would engage in response to rotation of rotating apparatus 44. The tool assembly can be pumped or lowered into a keyed logging position with sufficient wireline slack left in the conveyor between the side-entry sub and the tool assembly to accommodate the axial movement into logging position. The keyed logging position and clutch allow downhole radial control of portions of the tool assembly that require orientation but not centralization. The portions of the tool that must be centralized, such as sonic or acoustic-type tools, dip meters, and the like, are centralized on both ends and include two standard logging tool knuckle joints, one at the upper end of the centralized tool and one just outside the protective sleeve near the keyed seat. If centralization on the lower end of the tool assembly will provide sufficient accuracy, the upper centralizer and knuckle joint can be removed. In some instances, the keyed seat and mating tool insert can be made in a conical shape allowing movement over a small included angle around their longitudinal axes and eliminating the need for the logging tool knuckle joints. After logging is complete and the side-entry sub has arrived at the surface, the tool assembly can be pulled back into the protective sleeve. In addition to maintaining downhole control both radially and axially, a very important feature of this system is that in the process of logging, rigid tension is maintained throughout the drill string, protective sleeve, and tool assembly. Highly deviated holes require that centralized tools have very strong centralization springs in order to overcome the weight of the tools. Systems wherein a wireline is used as the conveyor, or in which a rigid conveyor is used and the logging tool assembly is secured to the conveyor either by way of a spring or wireline, can cause depth and log correlation problems as well as problems with accuracy from point to point over the interval of the formation. These problems are due to cable stretch. In highly deviated and tight vertical holes, cables stretch results in an ineffective log.
Further modifications and alternative embodiments of the apparatus of this invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the form of the invention herewith shown and described is to be taken as the presently preferred embodiment. Various changes may be made in the shape, size, and arrangement of parts. For example, equivalent elements or materials may be substituted for those illustrated and described herein, parts may be reversed, and certain features of the invention may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. | Disclosed is a downhole logging and servicing system with manipulatable logging and servicing tools. The system includes a conveyor for running the tools into and out of the well bore and a manipulating apparatus operable responsive to fluid pressure to manipulate the tools. The manipulating apparatus includes a fluid operated incremental rotating device connected to the conveyor and control device operated by the rotating device to manipulate the tools. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/CN2006/003317, filed Dec. 6, 2006. This application claims the benefit of Chinese Application No. 200510127458.4 filed Dec. 6, 2005. The disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present invention relates to Internet Protocol Television (IPTV) service techniques, and more particularly, to a system and method for IPTV service prompting.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Along with development of broadband network, stream media, coding/decoding, information encryption and memory technology, video service based on Transmission Control Protocol/Internet Protocol (TCP/IP) is implemented in commercial application. In industry, the video service based on IP and its relevant techniques, which are different from service based on Digital Video Broadcast (DVB), are named as IPTV (Internet Protocol Television) service.
[0005] An IPTV service system includes: an IPTV client and an IPTV server. Accordingly, the IPTV server, as a living broadcast TV source, provides the IPTV client with IPTV programs though a variety of channels. A web living broadcast software is installed on the IPTV client. The web living broadcast software is used for broadcasting movies and TV programs on network, and getting connected to an IPTV program sources in the IPTV server, and acquiring IPTV program data of certain channel for broadcasting. When a user uses the IPTV service, the user usually needs to browse program parade information several hours or days in advance, and watch the IPTV program via the web living broadcast software installed on the IPTV client when the IPTV program is broadcasted on the network.
[0006] However, in general, the user does not keep the web living broadcast software at work state during the whole day. Therefore, the user often forgets program airtime, and can not timely watch the IPTV program needed.
SUMMARY
[0007] Embodiment of the present invention provides a system for IPTV service prompting, and the system includes:
[0008] a first subsystem, for storing program information of each user;
[0009] a second subsystem, for determining the program information needed to be prompted according to the program information stored in the first subsystem.
[0010] The embodiment of the present invention also discloses a method for IPTV service prompting between system for IPTV service prompting and user client, and the method includes the following processes of:
[0011] searching, by a system for IPTV service prompting, program information of each user stored in the system for IPTV service prompting, and determining the program information needed to be prompted according to the program information searched, and outputting the program information needed to be prompted to a user client corresponding to a user of the program information needed to be prompted;
[0012] displaying, by the user client, the program information needed to be prompted or paying, by the user client, an IPTV program corresponding to the program information needed to be prompted.
[0013] Therefore, according to the system and method for IPTV prompting provided by the embodiment of the present invention, the program information needed by user can be dynamically maintained, the program information needed to be prompted can be automatically determined. So the IPTV client can timely prompt the user to watch the program, which greatly facilitates the use of the IPTV service.
[0014] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0015] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0016] FIG. 1 is a schematic diagram illustrating configuration of a system in an embodiment of the present invention.
[0017] FIG. 2 is a schematic diagram illustrating processing procedure of a method in another embodiment of the present invention.
DETAILED DESCRIPTION
[0018] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0019] An embodiment of the present invention provides a system for IPTV service prompting. The system for IPTV service prompting includes a program information subsystem and a program prompting subsystem. The program information subsystem is configured to store program information of each user, and configured to output the program information of each user to the program prompting subsystem. The program prompting subsystem is configured to determine the program information needed to be prompted according to the program information from the program information subsystem, and configured to send the program information needed to be prompted to a user client. Thus, the user is timely prompted by the user client to review the program information, or the user client directly runs a web living broadcast software to play an IPTV program according to the program information needed to be prompted. The system and the method of present invention are usually based on Internet technology, and in the embodiments of the present invention, the system and the method of present invention are implemented in the World Wide Web.
[0020] FIG. 1 is a schematic diagram illustrating configuration of a system in an embodiment of the present invention. As shown in FIG. 1 , a system for IPTV service prompting is connected with an IPTV client in an IPTV service system. The system for IPTV service prompting includes a program information subsystem and a program prompting subsystem. The program information subsystem statically stores a great deal of program information of users, and the program information subsystem only includes a program information database. Alternatively the program information subsystem can dynamically maintain program information of each user; each user can change its own program information at any moment; and the program information subsystem can also further receive, from the outside, and keep the program information of users. In the above situation, the program information subsystem includes a program information client, a program information server and a program information database. And the program prompting subsystem includes a prompting server, an information notification client and an information notification server.
[0021] In the above mentioned system, the program information client is configured to receive, from the outside, and send the program information of user to the program information server. And the program information client can receive, from the outside, program parade information. The program information client can further output and display the program parade information to the user, when a user requests the program parade information. The user obtains the program parade information by, for example, browsing WEB pages. And the user selects the program information needed by the user and inputs the program information needed by the user to the program information client. The program information server is configured to receive the program information of user from the program information client, and input the program information of user to the program information database for storage. The program information database is configured to store the program information of each user, receive a query request from a prompting server, and output the program information to the prompting server. The prompting server is configured to periodically search program information in the program information database via the query request, determine whether the program information needs to be prompted, determine the program information needed to be prompted at present, extract all the program information needed to be prompted from the program information database, and output the program information needed to be prompted to the information notification server. The information notification server is configured to receive, from the prompting server, and output the program information to the information notification client corresponding to user of the program information. The information notification client is configured to receive the program information from the information notification server, and output the program information received to the user client corresponding to the user of the program information. And the user client displays the program information to the user; or the user client runs a web living broadcast software and plays the corresponding IPTV program according to the program information. In this embodiment, the information notification server can be connected with at least one information notification client, each information notification client can correspond to at least one user, each user client can correspond to at least one user, and each information notification client can be connected with at least one user client. For the users corresponding to the information notification client, the user client corresponding to the user needs to be connected with the information notification client.
[0022] In the above mentioned embodiment, the user client may be any one of media playing client which can be used for playing IPTV program (e.g., IPTV client, Windows Media Player, Real Player, or Playing Point of SRTEAM (PPSTREAM)). And the information notification server and the information notification client can be any kind of server and client which can issue notification information according to a user ID. In general, an instant communication server and an instant communication client are taken respectively as the information notification server and the information notification client in this embodiment of the present invention, which ensures the timely prompting for the IPTV program. There is a variety of instant communication servers/clients which are not limited in this embodiment of the present invention.
[0023] There have been instant communication service and subscription prompting service in the industry; and the instant communication service allows implementing the instant communication in the Internet and the multiparty group communication via the point-to-point technique; and the subscription prompting service allows periodically sending the prompting message to the user according to the time subscribed by the user. So functions of the prompting server, the instant communication client and the instant communication server as described above can be implemented, and the implementation inside the above mentioned servers will not be described in detail in the following description.
[0024] Based on of the above mentioned system, the embodiment of the present invention also provides a method for IPTV service prompting, which is used in the system including the above mentioned system for IPTV service prompting and the user client. And in the embodiment of the present invention the user client is an IPTV client. The process of the method in the embodiment of the present invention and the operational principle of the system in the embodiment of the present invention are hereinafter described in detail with reference to FIG. 2 .
[0025] FIG. 2 is a schematic diagram illustrating processing procedure of a method in another embodiment of the present invention. As shown in FIG. 2 , the process includes steps as follows.
[0026] Step 201 : a program information client in a program information subsystem displays program parade information usually displayed in a program information list to a user.
[0027] Step 202 : according to the program parade information displayed at the program information client, the user selects from the program parade information the program information needed to be prompted. The program information client records the program information selected by the user, and sends the program information selected to a program information server, and the program information server sends the received program information selected by the user to a program information database for storage. The program information server can be connected with at least one program information client. And each of the program information client transfers the program information received to the program information server connected with the program information client.
[0028] The program information client and the program information server are usually based on Internet technology. For example, in the embodiments of the present invention, the system and the method of present invention are implemented in the World Wide Web. The program information client can, via a WEB system, transfers the program information selected by the user to the program information server at background. For example, the program information client submits the program information to the WEB-based program information server in a POST mode through Hypertext Transfer Protocol (HTTP). The program information server can, via a Common Gateway Interface (CGI) program, obtains the program information submitted by the program information client according to the HTTP. And the program information server, via an Application Interface (API) of the program information database, stores the program information received in a program information database at background which is based on the Structured Query Language (SQL) technique. Here, the program information at least includes one of the following information: user ID, channel ID, airtime, program name (e.g., sports news).
[0029] In the above step 201 and step 202 , the program information subsystem dynamically maintains the program information of the user. Then the program information subsystem can, at any moment, update the program information recorded in the program information database according to the program information input by the user.
[0030] Alternatively, the program information subsystem can statically maintain the program information of each user. In this situation, the program information subsystem can only include one program information database; a system operator pre-saves the program information customized by each user in the program information database, and the step 201 and step 202 can not be performed in this situation.
[0031] Step 203 : the prompting server in the program prompting system subsystem, in a preset period, searches the program information in the program information database, and performs the following steps 204 - 206 to the program information searched by the prompting server.
[0032] Step 204 : determine whether the prompting is needed for the currently program information searched by the prompting server; if so, proceed to step 205 ; otherwise, terminate the current procedure.
[0033] The process of determining whether the prompting is needed for the currently program information searched by the prompting server includes: prompting the server to poll an airtime field in specific program information recorded in the program information database at background, and working out, by comparison and calculation, the time difference between the airtime recorded in the airtime field and the actual time at present, determining whether this time difference is within a preset threshold, for example, 5 minutes; if so, it can be determined that the prompting is needed for the program information; otherwise, the prompting is not yet needed for the program information. And the time of the prompting server can be taken as the actual time at present for the above mentioned calculation; besides, the airtime field of the program information recorded in the program information database can be directly obtained by means of database development interface API, and the database development interface API makes use of SQL statement. The method for field inquiry is not limited by the embodiment of the present invention, but covered in protection scope of the present invention.
[0034] Step 205 : the program prompting subsystem sends the program information needed to be prompted at present to an IPTV client corresponding to the user of the program information. The program prompting subsystem, after the program information needed to be prompted is determined, can further delete the program information needed to be prompted from the program information database.
[0035] The process of sending program information to the IPTV client includes: prompting the server to send the program information needed to be prompted to an instant communication server; determining, by the instant communication server, the instant communication client corresponding to the user of the program information received according to a user ID in the program information received, and sending the program information received to the instant communication client determined; determining, by the instant communication client determined, the IPTV client corresponding to the user of the program information received according to the user ID in the program information received, and sending the program information received to the IPTV client.
[0036] The program information transmitted between the prompting server and the instant communication server, and the program information transmitted between the instant communication server and the IPTV client may be based on the Transmission Control Protocol (TCP) or User Datagram Protocol (UDP).
[0037] Step 206 : upon receipt of the program information, the IPTV client can process in the following two modes: I. displaying the program information for the user, for example, directly displaying the program information on screen of the IPTV client, then the user can be aware of the IPTV program to be played, and the user determine whether to run the web living broadcast software to watch the IPTV program. II. automatically running the web living broadcast software installed on the IPTV client; then the web living broadcast software can, according to a channel ID in the program information, connect with an IPTV program source corresponding to the channel ID on the IPTV server, and acquire IPTV program data from the IPTV program source and plays the IPTV program corresponding to the program information. In this embodiment, the IPTV client can transfer the channel ID to be played to the web living broadcast software by calling a Component Object Model (COM) interface of the web living broadcast software.
[0038] The process of connecting by the web living broadcast software to the IPTV program source, and the process of obtaining data from the IPTV program source to be played are not the technical problem be solved in the present invention, and the above mentioned processes can be implemented in the prior art, so no further description is provided here.
[0039] The above mentioned embodiment substantially includes the following three processes: I. the process of the program information subsystem dynamically maintaining the program information as described in step 201 and step 202 ; II. the process of the periodically searching the program information as described in step 203 ; III. the processes for the program information needed to be prompted as described in steps 204 - 206 . These three processes are independent, so the order of performing the three processes is not limited in the present invention.
[0040] To sum up, the use of the system and method of embodiment of the present invention allows timely prompting the user to watch the IPTV program to be played, which greatly facilitates use of the IPTV service. The solution in the embodiment of the present invention is good in implementation without much change in the existing IPTV service system, so that it has considerable commercial value and is worth being implemented.
[0041] The foregoing description is only preferred embodiments of the present invention, and is not for use in limiting the protection scope thereof. Any modification, equivalent replacement or improvement made under the spirit and principles of the present invention is included in the protection scope of the claims of the present invention. | The embodiment of the present invention discloses a system for IPTV service promoting. And the system includes: a first subsystem, for storing program information of each user; a second subsystem, for determining the program information needed to be prompted according to the program information stored in the first subsystem. The embodiment of the present invention also discloses a method for IPTV service promoting. According to the embodiment of the present invention, the user is timely prompted to get the IPTV program. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is application claims the benefit of provisional application Ser. No. 60/547,977, filed Feb. 26, 2004. The above noted application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The reinforced mat for unstable surfaces relates to pavement systems generally and more specifically to readily installed matting. A unique aspect of the present invention is a reinforcing grid with projections beneath a mat.
People, vehicles, and equipment encounter a wide variety of terrain. On foot, people traverse nearly all terrain from temperate forests and plains, beaches, swamps, to the arctic, mountains and deserts. Vehicles and equipment traverse most terrain but have limits. Vehicles and equipment have tracked or wheeled propulsion. Tracks provide their own bearing surface upon which road wheels travel. The road wheels are integral to the vehicle or equipment as is the track. Tracks allow vehicles and equipment access to sandy, wet, and unpaved areas but face limits in high slope areas like mountains. Tracks also tend to damage paved roads and to increase vehicle weight and operating costs. In contrast to tracks, wheeled vehicles drive directly upon the terrain and do not provide their own bearing surface. Wheels allow vehicles and equipment to travel at high speeds on paved or smooth surfaces but face limits on high slopes and unstable surfaces like mountains, beaches or mud. When the terrain's surface no longer bears the weight or motive forces of a wheeled vehicle, the vehicle becomes mired.
Once reinforced, a surface can usually bear wheeled vehicles. A variety of methods have sought to reinforce surfaces for wheeled vehicles. Older methods involved wooden tracks and stone causeways built across swamps and deserts. Newer methods involved interlocking metal sections placed upon a surface. The military developed this as a rapid runway repair method in numerous variations. Civilian methods have included a variety of woven fabrics and mats of organic and inorganic material for soil stabilization. Prior art designs placed mats upon unstable surfaces such as sand and mud. The mats supported wheeled vehicles of many kinds: trucks, cars, trailers, aircraft, golf carts, and wheelchairs for instance. To paraplegics and other wheelchair occupants, proper planning prevents poor performance. A wheelchair occupant chooses a route to avoid terrain with a high likelihood of miring a wheelchair.
The present art overcomes the limitations of the prior art. That is, the art of the present invention, a reinforced mat for unstable surfaces, prevents movement and rutting of a mat. Wheelchair occupants hold in high importance the performance of their equipment. With the application of the present invention, a wheelchair occupant can have a path on sandy beaches, sports paths and playgrounds, and upon wet and muddy terrain. The reinforced mat allows those with walking difficulties and wheelchair occupants to cross unstable surfaces. As an adaptive device, the reinforced mat for unstable surfaces performs to the satisfaction of wheelchair occupants and others, and expands the terrain accessible to them.
The difficulty in providing a reinforced mat for unstable surfaces is shown by a typical mat. The reinforced mat for unstable surfaces started with poly extruded matting P.E.M.® products used on many surfaces. Alone P.E.M.® matting products covered unstable surfaces but developed ruts and shifted position with the passage of many wheeled vehicles. Ruts would develop in the mats as the underlying surface deflected due to the weight of the vehicles. In some mats, narrow width wheels would pinch the mat material and bind the wheels. Ruts became an obstacle to wheelchairs.
Reinforced matting systems are known in the prior art. The military has used AM 2 matting for decades. AM 2 is an interlocking series of square plates with molded edges. The plates are at least three feet on a side, take much labor to install, and bear the weight of landing aircraft. The military has also used sheet metal punched with holes as sections. These sections assembled into a grid to make a runway in rough terrain. The sections required significant transportation assets for delivery and labor for installation or removal.
In civilian applications, matting comes in a variety of materials. Matting can be organic to stabilize terrain while permitting growth of vegetation. This matting sees use on hillsides and erosion control projects, but does not support vehicle traffic. Inorganic matting sees numerous uses. As solid sheets, matting can be staked to a surface however, vehicle traffic will move sheet matting out of position and permit ruts due to deflection of the ground surface beneath the sheet. As a perforated sheet, matting permits vehicle traffic but requires staking lest the traffic reposition the sheet. Perforated sheets permit ruts unless vegetative re-growth succeeds. Generally, matting requires separate staking to withstand vehicle traffic.
Thus, prior art devices do not provide for a device combining matting and staking into one material. The present invention does have a reinforcing lattice with projections beneath a mat.
SUMMARY OF THE INVENTION
Terrain with sand or moisture often hinders wheeled vehicles and equipment. Cars get stuck in sand or mud regularly as do wheeled carts. In particular, beaches, sandy playgrounds, and mud inhibit wheelchairs from certain terrain and reduce the quality of life for the wheelchair occupants and others. The present invention improves ground transfer and environmental adaptation as it adds a mat to the ground surface and as it increases access for wheelchair occupants to a variety of terrain. A porous flexible mat upon a lattice and projections extending from the lattice provide a more stable surface for wheel chairs. The projections engage the terrain as the wheel chairs cross the mat toward a destination. The mat further assists people having gait or stride difficulties as they walk upon unstable surfaces. Alternatively, the reinforced mat has projections in the form of spikes or hollow tubes, spaghetti like fibers, glue, heat welding, or spot welding to join the mat to the lattice, and a variety of patterns for the lattice.
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 new and improved reinforced mat for unstable surfaces.
Another object is to provide a reinforced mat that can be easily and efficiently manufactured and marketed to the consuming public.
Another object is to provide a reinforced mat that allows a wheelchair or other equipment to cross sandy or wet terrain without miring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a wheeled vehicle, such as a wheelchair, becoming mired upon sandy terrain;
FIG. 2 a shows an oblique view of the preferred embodiment of the reinforced mat constructed in accordance with the principles of the present invention having tubes as projections;
FIG. 2 b shows an oblique view of the preferred embodiment of the reinforced mat constructed in accordance with the principles of the present invention having spikes as projections;
FIG. 3 shows a plan view of the reinforced mat for unstable surfaces;
FIG. 4 shows a plan view of the underside of the reinforced mat for unstable surfaces; and,
FIG. 5 shows a side view of a wheel upon the reinforced mat for unstable surfaces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present art overcomes the prior art limitations by projections beneath a fibrous mat. Turning to FIG. 1 , vehicles and equipment encounter a variety of terrain from paved roads to submerged fords and conditions in between. Vehicles have tracks or wheels for propulsion. Tracked vehicles usually press ahead through all terrain. On the other hand, wheeled vehicles have their weight born on the terrain surface. Wet or granular surfaces readily become unstable, form ruts, and bear less vehicle weight. In particular, wheelchairs with narrow width wheels quickly get stuck in sand and mire in damp earth as shown in FIG. 1 . A wheelchair alone has limited environmental adaptation and requires heightened effort for ground transfer. In a ground transfer, people firmly plant their arms upon the ground and lift themselves into their wheelchairs.
Wheelchair occupants avoid beaches, wet trails, and damp paths due to the risk of becoming mired. A system to reduce the risk of wheelchairs becoming mired in sand and mud is shown in FIGS. 2A & 2B . The system paves the way to rehabilitate worn paths, trails, roads, and other support surfaces that impede travel by wheelchair occupants. Wheelchair occupants hold in high importance, the performance of their equipment. Added to an unstable surface, the system adapts the environment to improve access for wheelchair occupants and others. The system stabilizes the ground surface which makes transferring a person from the ground to a wheelchair or from a vehicle to a wheelchair easier. In a ground transfer, people firmly plant their arms upon the invention to lift themselves into their wheelchairs. The present invention improves and simplifies ground transfers for wheelchair occupants alone or with the help of others.
The system is a laminate of two layers. The top layer is a plastic mat 2 , such as P.E.M.® poly extruded mat made of PVC (polyvinyl chloride), that reduces slipping under wet conditions. The mat 2 exceeds minimum slip resistance specified in ASTM F-1677-96 for level and 3:1 slopes in wet and dry conditions. The mat 2 has porous construction that allows moisture, light, and air to pass. The porous mat 2 eliminates standing water and an antimicrobial agent reduces algal, mildew, fungal, and bacterial growth within the mat 2 . The mat 2 resists ultraviolet light and wind uplift, and withstands temperatures from −35° F. thru 180° F. The mat 2 withstands the weather and chemicals, and does not leach plasticizers.
The bottom layer is a lattice 3 of molded polypropylene with depending projections 4 . In the preferred embodiment, the projections 4 are hollow tubes as in FIG. 2A . In an alternate embodiment, spikes 5 are the projections 4 shown in FIG. 2B . The spikes 5 are conical in shape with the base of the shape upon the lattice 3 . In the preferred embodiment, the mat 2 is laminated to the lattice 3 using a high strength thermoplastic adhesive. The mat 2 joins the lattice 3 opposite from the depending projections 4 . In an alternate embodiment, the mat 2 joins to the lattice upon application of high temperature.
Over in FIG. 3 , the porous mat 2 has a construction of numerous fibers. The fibers appear like irregular spaghetti strands but, are made of a flexible plastic PVC. The strands loop and cross one another in a non-woven mat 2 with little apparent pattern. The strands form a mat 2 upon heat and pressure bonding.
Then in FIG. 4 , the lattice 3 has a grid of weft members 6 and perpendicular woof members 7 beneath the mat 2 . In the preferred embodiment, the woof members 7 are wider than the weft members 6 . Alternating woof members 7 have an applied reinforcement running lengthwise, i.e. perpendicular to the weft members 6 . The projections 4 depend from the woof members 7 and the projections 4 on adjacent woof members 7 are offset. In the preferred embodiment, the projections 4 are round hollow tubes. In an alternate embodiment, spikes 5 serve as the projections 4 .
The present invention has lower installation costs compared to traditional paving such as concrete, asphalt, brick and boardwalks that have higher material and labor costs. To utilize the present invention, an installer properly plans and selects the size and color for the reinforced mat 2 from the three foot and six foot wide rolls available in a variety of colors. The reinforced mat 2 simply unrolls to twenty five foot sections for splicing end to end or side to side. A crew then presses the reinforced mat 2 into an unstable surface where the projections 4 anchor the reinforced mat 2 . Wheeled vehicles can then cross the reinforced mat 2 upon an unstable surface as shown in FIG. 5 . A proper installation prevents the frustrations arising from a poorly performing matting system or existing surface. Wheelchair occupants and experienced construction crews know that proper planning prevents poor performance in many tasks.
Following use, the reinforced mat 2 removes readily for rolling and then storage. For example, on a beach, the reinforced mat 2 can be installed at low tide allowing access to the water's edge. As the tide advances, rolling back the reinforced mat 2 up the beach prevents the tide from depositing sand and debris upon the mat 2 . The reinforced mat 2 can be used anywhere an unstable surface requires reinforcement for an event, wheeled vehicles, wheeled equipment, or access by wheelchair occupants.
From the aforementioned description, a reinforced mat for unstable surfaces has been described. The reinforced mat for unstable surfaces is uniquely capable of resisting ruts while allowing access to unstable surfaces for wheeled vehicles and equipment. The reinforced mat for unstable surfaces and its various components may be manufactured from many materials including but not limited to polymers, polyvinyl chloride, polyethylene, ferrous and non-ferrous metals, their alloys, and composites.
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. | Terrain often hinders wheeled vehicles as cars mire in sand and wheeled carts in mud. Beaches, sandy playgrounds, and mud inhibit travel of wheelchairs. A reinforced mat upon a lattice of projections provides a stable surface for wheels and wheelchairs. The projections engage the terrain as the wheelchairs cross the mat toward a destination. Also, the projections take the form of spikes or hollow tubes, the mat has porosity or spaghetti like fibers, and the lattice has various patterns. The reinforced mat may be used with larger vehicles over a variety of terrain. | 4 |
This application is a divisional of U.S. patent application Ser. No. 07/905,296 filed Jun. 29, 1992, now abandoned, and is a divisional of U.S. patent application Ser. No. 08/724,581 filed on Sep. 30, 1996, now U.S. Pat. No. 6,023,834.
TECHNICAL FIELD
The present invention relates to an improved, spin-on high-pressure fluid filter of the type having a bead-lock arrangement in lieu of a rolled lock seam to secure the cover to the housing, wherein the improvement comprises the use of a low-cost cover assembly formed from stamped metal plates, as well as a method of assembly thereof.
BACKGROUND OF THE INVENTION
Spin-on filters have been employed in a variety of applications including hydraulic systems and engine lubrication systems. Such filters generally include a filter element within a housing with a cover or nut plate secured at one end of the housing by which the filter can be screwed onto or off of a filter head. A central opening surrounded by a plurality of smaller openings is provided in the cover to direct flow through the filter element contained within the housing of the filter. In an inside/out flow arrangement, pressurized, unfiltered fluid (such as the lubricating oil used in a diesel engine) enters the central opening and exits through the surrounding openings after passing through the filter element within the housing. In an outside/in flow pattern, the pressurized, unfiltered fluid enters the surrounding-openings and-exits through the central opening after passing through the filter element. A circular gasket is provided on a top surface of the cover to serve as a seal between the filter and the filter head. A spring is provided at the lower end of the housing to push the filter element in sealing engagement with the underside of the nut plate that forms the cover.
Although satisfactory in low and medium applications, generally spin-on filters of the prior art have not been satisfactory for use in high-pressure applications such as in hydraulic transmission pumps, where surges of 1,000 psi or more can occur. Most spin-on filters currently available include covers constructed of a stamped steel disk, and a relatively thinner secondary disk spot welded thereto. The base disk includes an extruded, relatively shallow, internally threaded neck portion by which the filter can be connected to a filter head. Flow openings are punched into the base disk around the neck portion. The lip at the open end of the housing is connected, by means of a rolled lock seam, to the periphery of the secondary disk which is also formed to serve as a seat for the external gasket. In this design, fatigue failure is most likely to occur at the rolled lock seam or at the spot welds. A burst failure is most likely to occur either upon bending of the cover (which allows leakage to pass the external gasket) or upon unfolding of the rolled seam. Thus, prior art spin-on filters have been susceptible to failure at the cover and/or at the connection between the cover and housing. Welding of the housing and cover is often unacceptable due to the incompatibility of housing and cover materials such that a satisfactory weld cannot be formed.
To solve these problems, the applicants developed a novel high-strength, spin-on filter in which a reliable and durable seal between the cover and the open end of the housing was achieved without the use of either a rolled lock seam, or a weld by means of a bead-lock arrangement. This filter is described and claimed in U.S. Pat. No. 5,080,787, assigned to the Fleetguard, Inc., the entire specification of which is incorporated herein by reference. In this particular filter, a round cover formed from die-cast metal is provided which is circumscribed around its outer edge by both an upper, C-shaped groove and a lower groove having a rectangular cross section which seats an O-ring. The die-cast cover further includes a centrally located, threaded aperture which can be screwed onto the nipple of a filter head, and a plurality of oil outlet openings surrounding the threaded, centrally-located aperture. On the top surface of the die-cast cover, a circular groove is provided which circumscribes the outlet openings that surround the threaded aperture. This groove receives a gasket which creates a seal between the top surface of the cover of the filter and the filter head when the threaded aperture of the filter cover is screwed onto the threaded nipple of the filter head. In the method of assembling this prior art filter, the filter element is first placed into the interior of the housing. An O-ring is then seated around the second groove which circumscribes the lower part of the die-cast cover, and the cover is then inserted into the open end of the housing until the C-shaped groove which circumscribes the upper portion of the housing is positioned adjacent to the upper periphery of the housing. A roller is then used to inwardly deform the metal around the periphery of the housing in conformance with the C-shaped groove in the cover in what is known in the art as a “spin beading” operation. The spin-beading secures-the cover to the housing without the need for rolled lock seams which, as previously pointed out, are proven to rupture when exposed to high pressures. The use of a spin-beading operation to secure the cover to the housing, instead of a lock seam, allows this filter to be assembled rapidly and inexpensively.
While the filter disclosed and claimed in U.S. Pat. No. 5,080,787 represents a substantial advance in the art, the applicants have observed two areas where improvement would be desirable. First, while the die-cast cover used in this filter works well for its intended purpose, it is unfortunately expensive as compared to covers formed from one or more stamped metal plates. Secondly, because the seal between the cover and the housing is dependent upon the proper compression of the O-ring between the cover and the housing, the dimensional tolerances of the O-ring, and the depth of the groove in the cover that seals it are narrow. These narrow tolerances prevent the substitution of a less precisely dimensioned, but lower cost lathe-cut gasket for the O-ring. Thirdly, when the cover is inserted into the open end of the housing incident to the assembly operation, shear forces are applied to the O-ring that has been previously seated around the lower circumferential groove of the cover which are capable of either damaging the O-ring, or rolling it out of the lower circumferential groove of the cover, thereby destroying the cover seal. While the application of a lubricant to the seated O-ring prior to the insertion of the cover into the housing solves much of this problem, it also adds an unwanted step in the assembly operation.
Clearly, it would be desirable if an improved filter could be developed which maintained all of the structural and assembly advantages associated with the filter disclosed and claimed in the '787 patent, but whose cover could be replaced with a lower cost cover assembly formed from stamped metal plates and lathe-cut gaskets. It would further be desirable if the assembly of such an improved filter did not apply unwanted shear forces onto any of the sealing O-rings or gaskets during the assembly of the filter, and did not require the application of any O-ring or gasket lubricants.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of assembly an improved filter which maintains all of the advantages associated with the filter disclosed and claimed in U.S. Pat. No. 5,080,787, but which is less expensive and easier to manufacture.
It is a further object of the invention to provide such an improved filter which utilizes a relatively inexpensive cover assembly formed from stamped metal plates and lathe-cut gaskets, and which does not require the application of any lubrication to the sealing gaskets.
Finally, it is an object of the invention to provide an improved method of assembling a filter in which none of the O-rings or sealing gaskets is subjected to shear forces; during the assembly of the filter which could either damage or misalign the sealing gaskets.
To this end, the filter of the invention comprises a method of assembling a filter including housing having a periphery that includes an inwardly deformed portion, and a cover assembly including a cover plate and a retainer plate having mutually spaced apart outer edges for forming a recess that receives the inwardly deformed portion of the housing. A gasket is disposed in the recess defined by the mutually spaced apart outer edges for effecting a seal between the outer edge of the cover assembly and the inwardly deformed portion of the housing when said portion is inwardly deformed incident to a spin-beading operation.
In the preferred embodiment, both the cover plate means and the retainer plate are formed from a stamped metal, such as steel. Additionally, the retainer plate further includes a deformed portion located inside of its outer edge that defines a groove for receiving a second gasket for effecting a seal between the cover assembly, and a filter head. One of the walls of the deformed portion of the retainer plate may function to compress the first gasket when this gasket is engaged by the spin-beaded portion of the housing. Finally, the deformed portion of the retainer plate may have an exterior portion that acts as a spacer to uniformly space apart the outer edges of the cover plate and retainer plate.
The outer edges of the retainer plate may be dimensioned to extend over the periphery of the housing to limit the extent to which the cover assembly may be inserted into the housing during the assembly thereof. These outer edges may be deformed into frictional engagement with the inwardly deformed portion of the housing to prevent relative rotation between the cover assembly and the filter housing when the filter is screwed into a nipple of a filter head.
The invention encompasses a method of forming such a fluid filter which comprises the steps of providing a filter housing as previously described, placing a filter element within the housing, forming a cover assembly with first and second plates by interconnecting the two plates together so that they have mutually spaced apart outer edges that define a recess, seating a gasket in the recess, inserting the cover assembly into the open end of the housing such that the periphery of the filter housing is adjacent to the recess, and deforming at least some of the housing periphery inwardly into the recess to both secure and seal the cover assembly to the housing.
The method of the invention may further comprise the step of stamping a deformed portion in the first plate that is offset with respect to the outer edge of the first plate and using this offset portion to uniformly space apart the outer edges of the first and second plates to form the recess. In the preferred method of the invention, the deformed portion of the first plate defines a groove, and the method further includes the step of seating a second gasket in the groove which forms a seal between the filter and a filter head when the filter is secured onto the head.
The improved filter allows the cover assembly to be made of inexpensive stamped steel plates, and further allows the substitution of a less expensive lathe-cut gasket for the O-ring used in the prior art. The improved filter also obviates the need for applying potentially damaging shear forces to the gasket that seals the cover assembly to the housing, or lubricants to minimize the damaging effects of such forces, as the gasket does not engage the housing until the bead rolling step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of the improved filter of the invention as it would appear mounted on a filter head;
FIG. 2 is a plan view of the improved filter of the invention with the filter head gasket removed;
FIG. 3 is an enlarged view of the portion of FIG. 1 enclosed by a dashed square, and
FIG. 4 is a cross-sectional side view of both the improved filter of the invention and the roller mechanism which inwardly deforms the upper peripheral portion of the filter housing to both secure and seal the cover assembly of the filter to the housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIGS. 1 and 2, the improved filter 1 of the invention is particularly adapted to be mounted in sealing engagement against a filter head 3 of the type typically used in the lubrication systems of diesel engines. Such a filter head 3 includes a centrally disposed threaded nipple 4 onto which the filter 1 is spun-on in sealing engagement.
The filter 1 itself generally comprises a cylindrical housing 5 formed from drawn steel, and a cover assembly 6 . The housing 5 includes an integrally formed, closed bottom end 7 , and a open top end 9 circumscribed by an upper peripheral portion 10 . An annular filter element 11 is disposed in the interior of the housing 5 . The filter element 11 is sealingly captured between top and bottom filter element retainers 13 and 15 , respectively. The top filter element retainer 13 includes a centrally disposed aperture 17 for admitting the distal end of the threaded nipple 4 of the filter head, as well as an annular recess 18 which receives the upper end of the filter element 11 . The bottom filter element retainer 15 includes a centrally disposed, circular wall 19 which is circumscribed by an annular recess 20 which in turn sealingly receives the bottom portion of the annular filter element 11 . A spring 21 applies a compressive force between the closed bottom end 7 of the housing 5 and the circular wall 19 of the bottom filter element retainer 15 in order to bias the top filter element retainer 13 in sealing engagement against an annular seal 23 . This seal 23 includes upper and lower flanges 24 a , 24 b for simultaneously sealing both the inner edge, and the inner top portion of the top filter element retainer 13 with respect to the outer diameter of the threaded nipple 4 , and the cover assembly 6 , respectively.
With reference now to FIGS. 2 and 3, the cover assembly 6 of the improved filter 1 generally comprises a relatively thick cover plate 25 (typically referred to as a “nut plate” in the art), in combination with an annular retainer plate 27 . Both the cover plate 25 and retainer plate 27 are preferably formed from stamped steel. The cover plate 25 has a central opening 29 for the admission of pressurized, unfiltered fluid (such as unfiltered lubricating oil) from the threaded nipple 4 of the filter head 3 . The central opening 29 is circumscribed by an annular bent portion 30 which terminates in a threaded flange 31 as shown. The screw threads on the flange 31 are, of course, compatible with the screw threads on the exterior of the threaded nipple 4 . Circumscribing the threaded flange 31 are a plurality of peripheral openings 33 which act as flow outlets for admitting a flow of filtered fluid back up into an annularly-shaped flow inlet 35 of the filter head 3 that is concentrically disposed around the exterior of the nipple 4 . The cover plate 25 terminates in an outer edge 37 whose diameter is slightly less than the inner diameter of the housing periphery 10 .
The retainer plate 27 of the cover assembly 6 includes a centrally disposed, circular opening 40 which is slightly smaller than the diameter of the flow inlet 35 of the filter head 3 . In its inner portion, the retainer plate 27 includes an annular deformed portion 42 having a U-shaped cross section as is most clearly seen in FIG. 3 . This U-shaped deformed portion 42 includes inner and outer side walls 43 a , 43 b , respectively, as well as a bottom wall 44 . The retainer plate 27 is affixed over the top surface of the cover plate 25 by a plurality of spot welds 45 between the bottom wall 44 of the U-shaped deformed portion 42 , and the top surface of the cover plate 25 . A filter head gasket 46 is seated within the U-shaped deformed portion 42 . This gasket 46 has an upper, tapered sealing surface 46 . 5 which is complimentary in shape to a frustro-conical shoulder 47 which extends down from and circumscribes the-flow inlet 35 of the filter head 3 . When the cover plate 25 of the cover assembly 6 is screwed onto the nipple 4 of the filter head 3 in the position illustrated in FIG. 1, the annular bent portion 30 of the cover plate 25 applies a compressive spring force against the bottom wall 44 of the U-shaped deformed portion 42 of the retainer plate 27 to squeeze the complimentary top surface 46 . 5 of the gasket 46 into seating engagement with the frustro-conical shoulder 47 of the filter head 3 . To prevent the inner and outer side walls 43 a, b from spreading in response to the compressive force applied to them by the filter head gasket 46 , the retainer plate 27 is further provided with inner and outer bead-like shoulders 49 and 51 at the top of the inner and outer side walls 43 a , 43 b , respectively. These shoulders 49 , 51 are preferably formed by stamping in order to work harden the upper portions of the side walls 43 a , 43 b , thereby rendering them stronger.
In its outer portion, the retainer plate 27 terminates in an outer edge 53 which overhangs the outer edge 37 of the cover plate 25 . This outer edge 53 is formed by inwardly bending a circular flange 55 that forms the outer edge of the retainer plate 27 prior to the assembly of the filter 1 , as may be best understood with reference to FIG. 4 . It is important to note that the outer diameter of the circular flange 55 of the retainer plate 27 is larger than the inner diameter of the upper peripheral portion 10 of the housing 5 such that the flange 55 limits the extent to which the cover assembly 6 may be inserted into the open top end 9 of the housing 5 during the assembly method.
The outer edges 37 and 53 of the cover plate and retainer plate, along with the outer side walls 43 b of the U-shaped deformed portion 42 , form a generally square recess 57 into which a gasket 59 having a generally rectangular cross section is seated. While virtually any gasket may be used in this application, gasket 59 is preferably of the inexpensive, lathe-cut variety in order to minimize the production expenses associated with the improved filter 1 . As may best be seen with respect to FIG. 3, the gasket 59 is compressed against the outer side wall 43 b of the U-shaped deformed portion 42 of the retainer plate 27 by a C-shaped, inwardly deformed portion of the housing periphery 10 in order to form an effective seal between the outer edge of the cover assembly 6 , and the upper peripheral portion 10 of the housing 5 .
In operation, the improved filter 1 is first mounted on the filter head 3 by screwing the threaded flange 31 over the threaded nipple 4 into the position shown in FIG. 1 . Pressurized, unfiltered fluid flows through the threaded nipple 4 and into the center portion of the interior of the housing 5 , where it is forced through the inner diameter of the annular filter element 11 . The sealing engagement between the top and bottom portions of the filter element 11 , and the bottom filter element retainer 15 , top filter element retainer 13 , and annular seal 23 , does not allow the pressurized fluid flowing in from the nipple 4 to flow anywhere but through the filter element 11 . Once the pressurized fluid has passed completely through the filter element 11 , it flows through the annular space defined between the outer diameter of the filter element 11 , and the inner diameter of the housing 5 , where it collects and eventually flows through the flow outlets 33 defined in the cover plate 25 . From the flow outlets 33 , the filter fluid then flows into the annular flow inlet 35 of the filter head 3 . The compressed, lathe-cut gasket 59 disposed between the cover assembly 6 and the upper peripheral portion 10 of the housing 5 prevents pressurized fluid from escaping through this inner face, while the filter head gasket 46 prevents filtered, pressurized fluid from flowing out between the inner face between the filter 1 , and filter head 3 .
The method of assembly of the filter 1 may best be understood with respect to FIG. 4 . Prior to assembly, the housing 5 is circumscribed by an orthogonally disposed, peripheral flange 63 (indicated in phantom). Similarly, the retainer plate 27 of the cover assembly is circumscribed by a circular flange 55 (again indicated in phantom) whose outer diameter is greater than the inner diameter of the upper peripheral portion 10 of the housing 5 . As has been previously indicated, the outer diameter of the outer edge 37 of the cover plate 25 is slightly less than the inner diameter of the upper peripheral portion 10 of the housing 5 . Prior to the insertion of the cover assembly 6 into the housing 5 , the lathe-cut gasket 59 is seated in the recess 57 defined between the outer edges 37 and 53 of the cover plate 25 and retainer plate 27 , respectively, and the outer side wall 43 b of the U-shaped deformed portion 42 of the retainer plate 27 . The outer diameter of the gasket 59 should be somewhat shorter than the outer diameter of the outer edge 37 of the cover plate 25 . Such dimensioning of the outer edges of the cover plate 25 , retainer plate 27 , and gasket 59 allows the cover assembly to be easily inserted over the open top end 9 of the housing 5 into position illustrated in FIG. 4 until the circular flange 55 of the retainer plate 27 abuts the peripheral flange 63 of the housing in the positions shown in phantom. Advantageously, during the cover insertion step of this method, no sheer forces of any kind are applied to the gasket 59 . As the cover assembly requires essentially no force to be inserted into the open top end 9 of the housing, the cover assembly is pushed down against the annular seal 23 with only enough force to overcome spring 21 .
After the cover assembly 6 has been inserted into the upper peripheral portion 10 of the housing 5 , a swaging roller 65 having a rounded edge 67 which terminates in a stepped portion 69 forcefully engages the upper peripheral portion 10 of the housing 5 to deform the peripheral flange 63 into the C-shaped deformed portion 61 . The inner diameter of this deformed portion 61 compresses the gasket 59 such that a fluid tight seal is formed between the outer edge 37 of the cover plate 25 , the outer side wall 43 b of the U-shaped deformed portion 42 on the retainer plate 27 , and the inner diameter of the C-shaped deformed portion 61 of the housing periphery 10 . This same C-shaped deformed portion 61 also further serves to mechanically interconnect the cover assembly 6 with the housing 5 by forming an interference type joint between the housing 5 , and the recess 57 defined between the outer edges of the cover plate 25 and retainer plate 27 , which in turn maintains the inner bent portion 30 of the cover plate 25 in sealing engagement against the annular seal 23 .
In the final step of the method of assembly, the circular flange 55 of the retainer plate 27 is folded around the top edge of the C-shaped deformed portion 61 of the housing periphery 10 into the position illustrated. Such a folding of the flange 55 accomplishes three purposes. First, it creates a smooth, rounded edge that covers the relatively sharp edge of the C-shaped deformed portion 61 , thereby rendering the improved filter 1 safer to manually handle. Secondly, it increases the mechanical coupling between the cover assembly 6 , and the housing 5 . Thirdly, it provides a final sealing barrier between the cover assembly 6 , and the housing 5 , should the seal formed by the gasket 59 fail.
Industrial Applicability
The present invention provides a high strength filter capable of withstanding high pressures without failure occurring between the filter housing and a cover assembly formed from low cost, stamped steel plates. The structure of the cover assembly allows it to be inserted into the housing without the application of shear forces to the sealing gasket. The filter housing is joined to the cover utilizing a simple spin beading operation which deforms the housing into a recess defined in the sidewall of the cover by the spaced apart outer edges of the stamped steel cover plate and retainer plate that forms the cover assembly, without substantially stretching or thinning of the housing sidewall. A single spin beading step both seals and couples the cover assembly to the housing. While the present invention is particularly suitable for filtering liquids in which high hydrostatic and hydrodynamic forces are incurred, it should be apparent to one of ordinary skill that inventive features are also applicable to other fluid filter applications. | An improved, spin-on, bead-lock filter which is particularly adapted for use in a high-pressure oil filter in a diesel engine is provided. The filter includes a housing containing a filter medium and having an inwardly deformed periphery, and a cover assembly including a cover plate and a retainer plate having mutually spaced apart outer edges for forming a recess that receives the inwardly deformed portion of the housing. A gasket whose outer diameter is less than the inner diameter of the undeformed housing is seated in the recess. The smaller outer diameter of the gasket relative to the inner diameter of the housing allows the cover assembly to be easily positioned in place over the top of the housing during manufacture. Both a mechanical connection and a seal is formed between the cover assembly and the housing when the periphery of the housing is inwardly deformed pursuant to a bead rolling step in conformance with the assembly method of the invention. | 1 |
This application is a continuation of application Ser. No. 07/134,835, filed Dec. 18, 1987, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a safety device for preventing injury to individuals or animals by stopping anything from entering an opening between a hinged door and the door frame, on either the front or rear face of the hinged side of a door.
The fingers and other body parts of countless children, adults and animals have been severely injured by being pressed between a door and its associated frame, due to inadequate safeguards. A prior art attempt to provide such a safe guard against injury is shown in U.S. Pat. No. 474,633. However, the device of this patent comprises a flat sheet of material which extends outwardly far from the door in some operative positions, and which is unattractive and obtrusive. Since only the flat main portion bends, relatively high forces are applied to the anchoring edges, requiring more secure and permanent types of anchoring.
Therefore, an object of this invention is to provide a simple, inexpensive, durable, reliable, unobtrusive and aesthetically pleasing safety or protective device for a door gap that can be added to an existing door and door frame, without damaging the door, the door frame or the adjacent molding.
Another object of the invention is to provide easy installation for the user, and to provide a door gap protective device that does not create high stresses or forces on the anchoring means for securing same in place.
A further object of the invention is to provide an easy-to-make, easy-to-store, easy-to-ship door gap protective device.
SUMMARY OF THE INVENTION
According to the present invention, a protective device for preventing injury by shielding body parts, particularly the fingers, from getting caught in either the front face or rear face gap at the hinged side of a door, comprises a flexible, protective member for continuously covering the gaps formed at the hinged side of a door when the door is opened and closed. One lateral edge of the protective member is fixedly attached to the molding or door frame or wall adjacent to the hinged side of the door. The protective member extends across the gap between the door and door frame or the like, to a point where the second lateral edge of the device is attached to the door. When the door is closed, at least one inwardly directed fold, curve, depression or re-entrant portion of the protective member placed on the front face of the hinged side of the door will be in its compacted or inwardly folded state. As the door is opened, the protective member will unfold or expand and cover the entire gap between the hinged side of the door and the door frame or the like, regardless of the degree of the opening of the door. The gap formed between the door and the door frame or the like is thus covered whether the door is completely or partially opened.
The same protective device can also be used on the rear face of the hinged side of the door. When the device is placed on the rear face of a closed door, the at least one inwardly directed fold, curve or depression or re-entrant portion is in its extended or unfolded state. The device returns to its compacted or folded state as the door is opened.
The protective device can cover the entire height of the door or any portion of the height thereof, and can be placed on either or both of the rear and front faces of the door.
The one or more folds, curves, depressions, re-entrant portions or joints of the protective member of the present invention reduces the pressure or force exerted on the lateral door and frame attachments and allow for a multitude of methods to be used for anchoring or attaching the protective device to the door and door frame or the like. This distribution or relief of pressure also reduces the chances of breakage or detachment from the door and/or door frame or the like. The sizes of the one or more folds, curves, depressions or re-entrant portions can vary from device to device to accommodate different sized doors. The distance between said one or more folds, curves, depressions or re-entrant portions can also vary on the same individual device, allowing for optimum folding or recoiling ability.
As used in the present description and claims, the term "door frame" means any structure to which a door is hinged. In some cases, for example, a door frame per se is not used - i.e., the door is hinged directly to a wall or other support structure. The term "door frame" thus includes any such structure to which a door is hingedly mounted.
As used in the present description and claims, the term "re-entrant" is used to generally designate any of the different inwardly directed portions of the protective members shown in the drawings and all equivalents thereof. Especially in the claims, the term "re-entrant" is so used for convenience and ease of description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the hinged side of a door showing one embodiment of the present invention attached on both the front and rear faces of a closed door;
FIG. 2 is a top view of the door arrangement of FIG. 1 showing the door partially opened;
FIG. 3 is a top view of the door arrangement of FIGS. 1 and 2 showing the door completely opened;
FIG. 4 is a front view of a door showing an embodiment of a protective device of the present invention attached to a closed door;
FIG. 5 is a front view of an embodiment of a protective device of the present invention attached to a partially opened door, and with the protective device extending up only partially from the bottom of the door;
FIG. 6 is a rear view of the partially opened door of FIG. 5.
FIG. 7 shows a "recoiling" re-entrant tube-type of protective device according to another embodiment of the present invention, attached to both the inner and outer faces of a closed door;
FIG. 8 shows the recoiling re-entrant tube-type device of FIG. 7 with the door opened;
FIG. 9 shows another type of recoiling re-entrant tube-type device according to the present invention which is similar to that of FIGS. 7 and 8;
FIG. 10 shows a front perspective view of a pair of accordion-folded-type of protective devices of the present invention, in a substantially folded form, in a condition ready for being packaged for shipping and/or storage, after manufacture;
FIG. 11 shows a top view of a pair of nested recoiling-type tubular members of FIGS. 7 and 8 in a compacted or coiled form, ready for packaging for shipping and/or storage after manufacture thereof; and
FIGS. 12-15 show top views of modified versions of protective devices according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a door 1 and the hinge side of the door frame 2 attached together by a hinge 3. A door frame 2 is specifically referred to herein. However, as stated hereinabove, the invention is equally applicable to doors hinged directly to a wall or the like, or other support structure, without using a door frame per se. The term "door frame" is being used generally to refer to any type of support structure to which a door is hingedly connected. Hinge 3 may be any well known type of door hinge. The gap 8 between the door 1 and door frame 2 is covered on the front face of the door 1 by the protective device 4 which is constructed of flexible, material which has a number of accordion-like folds 5 formed therein over at least a substantial portion of the width thereof, and preferably over at least a major portion of the width thereof.
One vertical flange 6 of the protective device 4 is attached to the door frame 2, preferably by an adhesive method so that it can easily be attached and which also causes substantially no damage to the door frame 2. A second vertical flange 7 is preferably adhesively attached to the door 1, so as not to damage the vertical hinged side of the door 1. Screws, nails, or the like could be used to attach the protective devices to the door and/or door frame, such as shown, for example, in U.S. Pat. No. 474,633. A substantially identical protective device 9 is attached to the opposite rear face of the door 1 in the same manner as was the protective device 4 on the front face of the door 1 and the door frame 2. The folds 5 on protective device 4 on the front face of the dcor 1 and frame 2 are in the folded, compressed or compacted state when the door.1 is closed. The folds 10 are in an extended or at least partially unfolded state on the rear face of the door 1 and door frame 2 when the door 1 is closed.
FIG. 2 illustrates the door 1 of FIG. 1 in a partially opened state with gaps 8 and 11 formed between the door 1 and the door frame 2. The protective device 4 on the front face of the door 1 has been extended by partial unfolding of the folds 5. The gap 8 is thus always completely covered over the height of protective device 4. The protective device 9 on the rear face folds or compresses or "pinches" in (i.e. becomes compacted) as the door 1 is partially opened and places the protective device 9 into a partially compressed or compacted state. The gap 11 on the rear face thus is continuously covered by the protective device 9 over the height of the protective device 9.
FIG. 3 shows the front face of the door 1 of FIGS. 1 and 2 in a fully opened state with the folds 5 of the protective device 4 extended or unfolded to a greater degree, completely covering the larger gap 8. The second protective device 9 on the rear face of the door 1 and door frame 2 is shown in a more compressed state with the folds 10 closely compacted together, completely covering the enlarged gap 11.
FIG. 4 depicts the protective device 4 of the present invention covering the gap that exists between the closed door 1 and the door frame 2, and covering the gap which will be formed when the door 1 is opened. The protective device 4 is shown in its compressed state covering the gap along the total height of the door 1.
FIG. 5 shows a front view of a protective device 14 of the present invention covering the enlarged gap 8 of a partially open door 1. The protective device 14 has its folds 15 in a partially extended or unfolded state and is connected to door 1 and door frame 2 by flanges 17, 16, respectively, preferably by means of adhesive. The protective device 14 is identical to device 4 of FIGS. 1-4, but covers only a portion of the height of the door gap.
FIG. 6 is a rear view of the partially open door 1 of FIG. 5, showing a second protective device 19 in a state where the folds 20 thereof are in a slightly coiled or unfolded position. Protective device 19 only covers a portion of the height of the door gap but is otherwise identical to device 9. Protective device 19 could be lengthened to extend over the full height of the door gap.
FIG. 7 shows an alternate embodiment wherein the protective device 22 comprises a recoiling-type tube 22 (actually part of a tube but generally designated herein as a "tube") that functions with one re-entrant (inwardly directed) portion 25, such as a fold or gently curved portion (see FIG. 9) therein. The fold 25 of FIG. 7 or inwardly curved portion (FIG. 9) is retractable as will be clear from the following. The lateral vertical flanges 23 and 24 of recoiling-type tube 22 are attached to the door 1 and door frame 2, respectively, in the same manner as previously described with respect to the
protective devices of FIGS. 1-6. The recoiling-type tube 22 with its inwardly directed re-entrant portion continuously covers the gap 8, thereby preventing anything from getting caught in a closing door.
As the door of FIG. 7 opens, the recoiling tube device 22 is extended outward at the single fold or re-entrant portion 25. FIG. 8 shows a partially opened door with the recoiling tube 22 slightly uncoiled and extending completely over the increased gap 8. The size of the fold 25 in the recoiling tube device 22 will be such that the device 22 will cover the gap 8 of a completely opened door. As is shown in FIGS. 7 and 8, a similar recoiling tube device 26 can be placed on the rear face of the door 1 and door frame 2 to cover the rear gap 11. As seen in FIGS. 12-15 more than one fold, curve or re-entrant portion can be formed in one or both of recoiling tube-type devices 22 and 26, as desired.
FIG. 9 shows recoiling tube-type devices 32,36, which are similar to recoiling tube-type devices 22 and 26 of FIGS. 7 and 8, except that the re-entrant fold 25 of FIGS. 7 and 8 is replaced with a curved inwardly directed recoiling portion 35, which is preferably gently curved. In other respects operation of the FIG. 9 embodiment is substantially similar to that of FIGS. 7 and 8.
FIG. 10 illustrates a pair of protective devices of the type shown in FIGS. 1-4, in their compacted state, ready for packaging for shipping and/or storage after manufacture thereof. The devices of FIG. 10 can be more fully compacted, as desired, by pressing the folds closer together. As can be seen from FIG. 10, two of said protective devices (a pair is required for full protection of a given door) can be compactly packaged and shipped, thereby providing a high degree of economy and conservation of space.
FIG. 11 shows a pair of the recoiling-type protective devices of FIGS. 7 and 8 shown in a compacted condition ready for packaging for shipping and/or storage. They can be compacted further, as desired. This also demonstrates the unique capability of the devices of the present invention to be compactly arranged after manufacture to increase economy of shipping and storage. The protective devices 32, 36 of FIG. 9 would be arranged in their compacted form for shipping and/or storage in a manner similar to that shown in FIG. 11.
While the preferred embodiments of the present invention are described, it is to be understood that these embodiments are given only by way of example, and that they are capable of variation and modification. An example of possible modification would be to have folds 5, 10, 15 and 25 of various different sizes on a single protective device in order to maximize the folding/unfolding, coiling/recoiling (i.e. compaction and extension) of the protective device. Also, the folds or accordian-type portions need not be provided over the complete width of the protective devices of the present invention. They can be provided, if desired, over a central width portion, the outer portions being substantially straight, provided that sufficient folds or re-entrant portions are provided to permit the protective member to be compressed or folded sufficiently that the protective member remains close to the door and door frame, without excessive "blousing".
Furhter modifications are illustrated in FIGS. 12-15, which show top views of modified protective members of the present invention. The protective members are shown on only one side of the door in FIGS. 12-15. It should be clear that they may be provided on both sides of the door, as shown in FIGS. 1-8. The protective members of FIGS. 12.are generally mushroom-shaped in top view, as clearly seen in FIGS. 12-15. Also, the protective devices of FIGS. 12-15 may extend either over the complete height of the door, or only over a part of the height of the door, such as shown, for example, in any of FIGS. 4-6. In FIG. 12, the protective member 40 has two bent re-entrant portions (curved) 41 and 42, and is attached to the door and door frame by flanges 43, 44, preferably by means of an adhesive. In FIG. 13, the protective member 50 is similar to that of FIG. 12, but it has a flat outer portion 51. This device is also connected tc the door and door frame by means of flanges 53, 54, preferably by means of an adhesive. The protective member 60 of FIG. 14 has bent re-entrant folds or angled portions 61, 62, and is also connected to the door and door frame by means of an adhesive at flanges 63, 64. The protective member 70 of FIG. 15 is similar to that of FIG. 14, but the bent re-entrant folds or angled portions 71, 72 have longer, substantially straight portions which are folded against each other over a longer distance. This provides a more compact arrangement than the arrangement of FIG. 14.
In any of FIGS. 12-14, the bent re-entrant portions may be curved portions, folds, angled portions, etc., as desired.
The device of the present invention is preferably fabricated of a flexible plastic sheet-like material (preferably semi-rigid), such as polyethylene. Such materials are relatively flexible, but provide sufficient rigidity and "springiness" to be mounted as shown in the drawings and to provide the desired folding/unfolding and/or recoiling effect. Since the materials are relativelY soft and flexible, a body part, even if caught in a fold or re-entrant portion will not be damaged or hurt.
As stated above, the term "re-entrant" is intended to encompass the folds (such as shown in FIGS. 1-6), recoiling members (such as shown in FIGS. 7-9 and 12-15) and any other type of similar or equivalent member having one or more inwardly directed (i.e., re-entrant) and retractable folds or curved or angled portions, to provide the expansion and compression, folding/unfolding, and/or recoiling effect of the present invention, as described hereinabove. | A finger, hand and other body part protector for hinged doors comprises an aesthetically pleasing foldable protective member which may be accordion-like, in the shape of a recoiling tube, etc., that extends over at least a portion of the height of the front and/or rear face opening or gap on the hinged side of a door. The device automatically expands and contracts to cover gaps created by the opening and closing of the door in a highly unobtrusive manner, thereby providing protection against insertion of body parts or the like into said gaps and resultant injury when the door is closed. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a clinical thermometer with a maximum function and a eutectic mixture suited to it.
2. Description of the Related Art
In order to achieve the maximum function, conventional thermometers of this kind are filled with mercury and show a constriction between the bulb exposed to the temperature to be measured and the reading or measuring tube, which has the effect that in the cooling down process the mercury thread that entered the measuring tube separates.
Mercury is extremely poisonous and for health and environmental reasons is therefore increasingly met with disapproval.
Furthermore, in making the thermometer, an additional production step is necessary in order to create the constriction which requires a certain amount of precision so that the necessary inner cross-section is achieved which has to be small to facilitate the separation of the mercury thread upon a drop in temperature after having reached the maximum temperature, but not so small as to interfere with the reuniting of the mercury upon shaking down.
In accordance with US-PS 3,872,729 it was suggested to do without the problematic constriction and to coat the inside of the measuring tube to assure the necessary adhesion forces. The production of such a measuring tube is, however, very expensive and usually not very practical. Furthermore, it is necessary also with this thermometer to rely on toxic mercury.
So far, all attempts to produce a mercury-free clinical thermometer failed first of all because of the necessary maximum function. Similarly unsuitable are also the thermometers according to DE-PS 453 184, DE-PS 454 213 and GB-PS 246 843, which provide for the use of gallium with and without indium. Such thermometers have the disadvantage that their measuring liquid solidifies at low temperatures which may under certain circumstances result in the thermometer shattering.
Similar problems also arise when using a measuring liquid according to SU-PS 279 108.
The object of the present invention is therefore to specify the details of a thermometer with a maximum function which is simple to use, easy to produce and is harmless from the health and environmental standpoint.
SUMMARY OF THE INVENTION
According to the invention the solution to the given problems is found by using a eutectic alloy containing gallium in a concentration of 65-95 wt.-%, indium in a concentration of 5-22 wt.-% and tin in a concentration of 0-11 wt.-%, if necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one embodiment of a clinical thermometer in accordance with the subject invention.
FIG. 2 illustrates a cross-sectional view of the embodiment of the clinical thermometer of FIG. 1 taken across the region 16 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The use of a eutectic gallium alloy as measuring liquid is of special significance because of its non-toxic characteristic. Furthermore, this liquid has a low melting point and a high vaporization point so that the necessary requirements of a clinical thermometer are met.
In this range of composition the liquid state of aggregation of the liquid extends from approx. -15° C. to more than +1800° C. under normal conditions. Gallium, indium and, if necessary, tin are preferential alloy elements because they lead to a particularly low eutectic point. Furthermore, this alloy is capable of conducting electricity so that it is also suitable for an embodiment as contact thermometer.
In a further embodiment of the present invention according to claim 2 the eutectic alloy may contain up to 2 wt.-% bismuth and up to 2 wt.-% antimony. Antimony raises the oxidation resistance while bismuth positively affects the fluidity of the alloy. Furthermore, antimony and bismuth are, like tin, readily available and inexpensive substances, while gallium and indium are expensive. A content of more than 2 wt.-% pf one of the two additional elements Sb and Bi leads to a noticeable and undesirable increase in the melting point.
In order to keep the liquid used for measuring and reading in the position of maximum wetting of the measuring tube, the adhesion forces inside the measuring tube must be greater than the cohesion forces active in the liquid. This is achieved, among others, by a water coat around the surface area of the measuring tube in contact with the liquid. Preferably this water coat is smaller than the permanent water coat which is normally on the surface of the measuring tube, so that a thin gallium oxide layer is formed by reaction of gallium in the liquid with the water, which deposits on the surface of the measuring tube, increasing the adhesion forces inside the measuring tube. In this respect, one can do without the conventional constriction which simplifies not only the production but also the handling of the thermometer when deliberately returning the measuring thread.
One of the possible embodiments of the thermometer according to the invention has the measuring tube made of glass. It may show a non-circular preferably flat-oval to crescent-shaped cross-section. These characteristics serve to increase the adhesion forces between the measuring liquid and the measuring tube and therefore to guarantee when temperature decreases that the liquid thread is kept in place in the measuring tube which is necessary in order to achieve the desired maximum function.
In a preferred embodiment, the actual measuring tube is connected to the bulb by an area which has an opening with a preferably circular cross-section in order to reduce the adhesion forces there. This results in a high operational reliability of the maximum function.
Thermometers with a measuring tube having a flat or crescent-shaped cross-section are known. This cross-sectional form has, however, so far been applied in the widening and improved readability of the mercury thread and not in increasing the adhesion.
In further embodiments, the outer wall of the clinical thermometer, e.g. the glass housing enclosing the tube, may be provided with a grip element which is formed by several glass mass areas melted onto the housing to improve the grip of the thermometer. Preferably said melted-on glass mass areas are arranged in the form of one or more circumferential rings around the housing. When using colored glass mass or glass paint a marking function, e.g. of the measuring range, or a reference that the clinical thermometer is filled with a non-toxic liquid can also be obtained.
Surprisingly it was found that a preferred eutectic mixture which contains 68-69 wt.-% gallium, 21-22 wt.-% indium and 9.5-10.5 wt.-% tin may be used for various other applications due to its special characteristics. Such a eutectic mixture is e.g. suitable as a lubricant especially for vacuum, high-vacuum and ultra-high vacuum applications.
The eutectic mixture according to the invention should, if possible, only have a small degree of impurity such as lead or zinc of less than 0.001 wt.-% , preferably less than 0.0001 wt.-%.
Said new eutectic mixture is mainly characterized by its low melting point of approx. -19.5° C. under normal pressure and atmospheric conditions. Furthermore, the vaporization point is above 1800° C.
According to the drawing, glass housing 10 encloses a bulb 11 with a measuring tube 13 arranged above the transition area 12. Bulb 11 is filled with said eutectic gallium alloy 14, which, as shown in FIG. 1, has risen inside measuring tube 13 to a certain height as a function of the temperature increase. The measuring tube area of the housing is provided with a scale 15.
Measuring tube 13 has, as shown in FIG. 2, a oval to nearly crescent-shaped cross-section to increase the adhesion between liquid 14 and measuring tube 13. Transition area 12 has an opening with a preferably circular cross-section to reduce the adhesion forces in this area ensuring the desired maximum function.
In the vicinity of the end opposing bulb 11 ten small irregular glass mass areas 16 are melted onto the outside of housing 10 forming one or more circumferential ring(s) around housing 10. Theses ring(s) does not only improve grip in this area of housing 10 but may also be used for colour coding. | A clinical thermometer registers the maximum temperature reached and uses as the thermometric fluid a non-toxic gallium/indium alloy which adheres to the walls of the thermometer measuring tube, the adhesive force being greater than the internal cohesive force of the thermometric liquid. A Gallium/indium/tin eutectic alloy is particularly useful in such applications and others. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 60/728,296, filed Oct. 20, 2005, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to audio time scale modification algorithms.
2. Background
In the area of digital video technology, it would be beneficial to be able to speed up or slow down the playback of an encoded audio signal without substantially changing the pitch or timbre of the audio signal. One particular application of such time scale modification (TSM) of audio signals might include the ability to perform high-quality playback of stored video programs from a personal video recorder (PVR) at some speed that is faster than the normal playback rate. For example, it may be desired to play back a stored video program at a 20% faster speed than the normal playback rate. In this case, the audio signal needs to be played back at 1.2× speed while still maintaining high signal quality. However, the TSM algorithm may need to be of sufficiently low complexity such that it can be implemented in a system having limited processing resources.
One of the most popular types of prior-art audio TSM algorithms is called Synchronized Overlap-Add, or SOLA. See S. Roucos and A. M. Wilgus, “High Quality Time-Scale Modification for Speech”, Proceedings of 1985 IEEE International Conference on Acoustic, Speech, and Signal Processing , pp. 493-496 (March 1985), which is incorporated by reference in its entirety herein. However, if this original SOLA algorithm is implemented as is for even just a single 44.1 kHz mono audio channel, the computational complexity can easily reach 100 to 200 mega-instructions per second (MIPS) on a ZSP400 digital signal processing (DSP) core (a product of LSI Logic Corporation of Milpitas, Calif.). Thus, this approach will not work for a similar DSP core that has a processing speed on the order of approximately 100 MHz. Many variations of SOLA have been proposed in the literature and some are of a reduced complexity. However, most of them are still too complex for an application scenario in which a DSP core having a processing speed of approximately 100 MHz has to perform both audio decoding and audio TSM.
Accordingly, what is desired is a high-quality audio TSM algorithm that provides the benefits of the original SOLA algorithm but that is far less complex, such that it may be implemented in a system having limited processing resources.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a high-quality, low-complexity audio time scale modification (TSM) algorithm useful in speeding up or slowing down the playback of an encoded audio signal without changing the pitch or timbre of the audio signal. A TSM algorithm in accordance with an embodiment of the present invention uses a modified version of the original synchronized overlap-add (SOLA) algorithm that maintains a roughly constant computational complexity regardless of the TSM speed factor. A TSM algorithm in accordance with an embodiment of the present invention also performs most of the required SOLA computation using decimated signals, thereby reducing computational complexity by approximately two orders of magnitude.
An example implementation of an algorithm in accordance with the present invention achieves fairly high audio quality, and can be configured to have a computational complexity on the order of only 2 to 3 MIPS on a ZSP400 DSP core. The memory requirement for such an implementation naturally depends on the audio sampling rate, but can be controlled to be below 4 kilowords per audio channel.
In particular, an example method for time scale modifying an input audio signal in accordance with an embodiment of the present invention is provided herein. The method includes various steps. First, a waveform similarity measure or waveform difference measure is calculated between a decimated portion of a second waveform segment of the input audio signal and each of a plurality of portions of a decimated first waveform segment of the input audio signal to identify an optimal time shift in a decimated domain. Then, an optimal time shift is identified in an undecimated domain based on the identified optimal time shift in the decimated domain. After this, a portion of the first waveform segment identified by the optimal time shift in the undecimated domain is overlap added with the portion of the second waveform segment to produce an overlap-added waveform segment. Finally, at least a portion of the overlap-added waveform segment is provided as a time scale modified audio output signal.
Furthermore, a system for time scale modifying an input audio signal in accordance with an embodiment of the present invention is also described herein. The system includes an input buffer, an output buffer, and time scale modification (TSM) logic coupled to the input buffer and the output buffer. The TSM logic is configured to decimate a first waveform segment of the input audio signal stored in the output buffer by a decimation factor to produce a decimated first waveform segment and to decimate a portion of a second waveform segment of the input audio signal stored in the input buffer by the decimation factor to produce a decimated portion of the second waveform segment. The TSM logic is further configured to calculate a waveform similarity measure between the decimated portion of the second waveform segment and each of a plurality of portions of the decimated first waveform segment to identify an optimal time shift in a decimated domain and to identify an optimal time shift in an undecimated domain based on the identified optimal time shift in the decimated domain. The TSM logic is still further configured to overlap add a portion of the first waveform segment identified by the optimal time shift in the undecimated domain with the portion of the second waveform segment to produce an overlap-added waveform segment and to store at least a portion of the overlap-added waveform segment in the output buffer for output as a time scale modified audio output signal.
An alternative system for time scale modifying an input audio signal in accordance with an embodiment of the present invention includes an input buffer, an output buffer, and time scale modification (TSM) logic coupled to the input buffer and the output buffer. The TSM logic is configured to decimate a first waveform segment of the input audio signal stored in the output buffer by a decimation factor to produce a decimated first waveform segment and to decimate a portion of a second waveform segment of the input audio signal stored in the input buffer by the decimation factor to produce a decimated portion of the second waveform segment. The TSM logic is further configured to calculate a waveform difference measure between the decimated portion of the second waveform segment and each of a plurality of portions of the decimated first waveform segment to identify an optimal time shift in a decimated domain and to identify an optimal time shift in an undecimated domain based on the identified optimal time shift in the decimated domain. The TSM logic is still further configured to overlap add a portion of the first waveform segment identified by the optimal time shift in the undecimated domain with the portion of the second waveform segment to produce an overlap-added waveform segment and to store at least a portion of the overlap-added waveform segment in the output buffer for output as a time scale modified audio output signal.
Additionally, a computer program product in accordance with an embodiment of the present invention is described herein. The computer program product includes a computer useable medium having computer program logic recorded thereon for enabling a processor in a computer system to time scale modify an input audio signal. The computer program logic includes first, second, third and fourth means. The first means are for enabling the processor to calculate a waveform similarity measure between a decimated portion of a second waveform segment of the input audio signal and each of a plurality of portions of a decimated first waveform segment of the input audio signal to identify an optimal time shift in a decimated domain. The second means are for enabling the processor to identify an optimal time shift in an undecimated domain based on the identified optimal time shift in the decimated domain. The third means are for enabling the processor to overlap add a portion of the first waveform segment identified by the optimal time shift in the undecimated domain with the portion of the second waveform segment to produce an overlap-added waveform segment. The fourth means are for enabling the processor to provide at least a portion of the overlap-added waveform segment as a time scale modified audio output signal.
An alternative computer program product in accordance with an embodiment of the present invention includes a computer useable medium having computer program logic recorded thereon for enabling a processor in a computer system to time scale modify an input audio signal. The computer program logic includes first, second, third and fourth means. The first means are for enabling the processor to calculate a waveform difference measure between a decimated portion of a second waveform segment of the input audio signal and each of a plurality of portions of a decimated first waveform segment of the input audio signal to identify an optimal time shift in a decimated domain. The second means are for enabling the processor to identify an optimal time shift in an undecimated domain based on the identified optimal time shift in the decimated domain. The third means are for enabling the processor to overlap add a portion of the first waveform segment identified by the optimal time shift in the undecimated domain with the portion of the second waveform segment to produce an overlap-added waveform segment. The fourth means are for enabling the processor to provide at least a portion of the overlap-added waveform segment as a time scale modified audio output signal.
A method for time scale modifying a plurality of audio signals, wherein each of the audio signals is associated with a different audio channel, is further provided. The method includes down-mixing the plurality of audio signals to produce a mixed-down audio signal, calculating a waveform similarity measure or waveform difference measure to identifying an optimal time shift between first and second waveform segments of the mixed-down audio signal, and overlap adding first and second waveform segments of each of the plurality of audio signals based on the optimal time shift to produce a plurality of time scale modified audio signals. Calculating a waveform similarity measure or waveform difference measure to identify an optimal time shift between first and second waveform segments of the mixed-down audio signal may include calculating the waveform similarity measure or waveform difference measure in a decimated domain.
Further features and advantages of the present invention, as well as the structure and operation of various embodiments thereof, are described in detail below with reference to the accompanying drawings. It is noted that the invention is not limited to the specific embodiments described herein. Such embodiments are presented herein for illustrative purposes only. Additional embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the relevant art(s) to make and use the invention.
FIG. 1 an example audio decoding system that uses a time scale modification algorithm in accordance with an embodiment of the present invention.
FIG. 2 illustrates an example arrangement of an input signal buffer, time scale modification logic and an output signal buffer in accordance with an embodiment of the present invention.
FIG. 3 is a conceptual illustration of the input-output timing relationship using a traditional Overlap-Add (OLA) method.
FIG. 4 is a conceptual illustration of an input-output timing relationship using a modified Synchronized Overlap-Add (SOLA) method in accordance with an embodiment of the present invention.
FIG. 5 is a flowchart of a modified SOLA algorithm in accordance with an embodiment of the present invention.
FIG. 6 is a flowchart of a modified SOLA algorithm in accordance with an alternative embodiment of the present invention.
FIG. 7 is an illustration of an example computer system that may be configured to perform a time scale modification method in accordance with an embodiment of the present invention.
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number.
DETAILED DESCRIPTION OF THE INVENTION
1. Introduction
In this detailed description, the basic concepts underlying traditional Overlap-Add (OLA) and Synchronized Overlap-Add (SOLA) algorithms as well as some basic concepts underlying a modified SOLA algorithm in accordance with the present invention will be described in Section 2. This will be followed by a detailed description of an embodiment of the inventive modified SOLA algorithm in Section 3. Next, in Section 4, alternative input/output buffering schemes with trade-off between programming simplicity and efficiency in memory usage will be described. In Section 5, the use of circular buffers to eliminate shifting operations in an embodiment of the present invention is described. In Section 6, a specific example configuration of a modified SOLA algorithm in accordance with an embodiment of the present invention that is intended for use with an AC-3 audio decoder operating at a sampling rate of 44.1 kHz and a speed factor of 1.2 will be described. In Section 7, some general issues of applying time scale modification (TSM) to stereo or general multi-channel audio signals will be discussed. In Section 8, the possibility of further reducing the computational complexity of a modified SOLA algorithm in accordance with an embodiment of the present invention will be considered. In Section 9, an example computer system implementation of the present invention is described. Some concluding remarks will be provided in Section 10.
2. Basic Concepts
2.1. Example Audio Decoding System
FIG. 1 illustrates an example audio decoding system 100 that uses a TSM algorithm in accordance with an embodiment of the present invention. In particular, and as shown in FIG. 1 , example system 100 includes a storage medium 102 , an audio decoder 104 and time scale modifier 106 that applies a TSM algorithm to an audio signal in accordance with an embodiment of the present invention. From the system point of view, TSM is a post-processing algorithm performed after the audio decoding operation, which is reflected in FIG. 1 .
Storage medium 102 may be any medium, device or component that is capable of storing compressed audio signals. For example, storage medium 102 may comprise a hard drive of a Personal Video Recorder (PVR), although the invention is not so limited. Audio decoder 104 operates to receive a compressed audio bit-stream from storage medium 102 and to decode the audio bit-stream to generate decoded audio samples. By way of example, audio decoder 104 may be an AC-3, MP3 or AAC audio decoding module that decodes the compressed audio bit-stream into pulse-code modulated (PCM) audio samples. Time scale modifier 106 then processes the decoded audio samples to change the apparent playback speed without substantially altering the pitch or timbre of the audio signal. For example, in a scenario in which a 1.2× speed increase is sought, time scale modifier 106 operates such that, on average, every 1.2 seconds worth of decoded audio signal is played back in only 1.0 second. The operation of time scale modifier 106 is controlled by a speed factor β. In the foregoing case where a 1.2× speed increase is sought, the speed factor β is 1.2.
It will be readily appreciated by persons skilled in the art that the functionality of audio decoder 104 and time scale modifier 106 as described herein may be implemented as hardware, software or as a combination of hardware and software. In an embodiment of the present invention, audio decoder 104 and time scale modifier 106 are integrated components of a device, such as a PVR, that includes storage medium 102 , although the invention is not so limited.
In one embodiment of the present invention, time scale modifier 106 includes two separate long buffers that are used by TSM logic for performing TSM operations as will be described in detail herein: an input signal buffer x(n) and an output signal buffer y(n). Such an arrangement is depicted in FIG. 2 , which shows an embodiment in which time scale modifier 106 includes an input signal buffer 202 , TSM logic 204 , and an output signal buffer 206 . In accordance with this arrangement, input signal buffer 202 contains consecutive samples of the input signal to TSM logic 204 , which is also the output signal of audio decoder 104 . As will be explained in more detail herein, output signal buffer 206 contains signal samples that are used to calculate the optimal time shift for the input signal before an overlap-add operation, and then after the overlap-add operation it also contains the output signal of TSM logic 204 .
2.2. The OLA Algorithm
To understand the modified SOLA algorithm in accordance with the present invention, one needs first to understand the traditional SOLA method, and to understand the traditional SOLA method, it would help greatly to understand the OLA method first. In OLA, a segment of waveform is taken from an input signal at a fixed interval of once every SA samples (“SA” stands for “Size of Analysis frame”), then it is overlap-added with a waveform stored in an output buffer at a fixed interval of once every SS samples (“SS stands for “Size of Synthesis frame”). The overlap-add result is the output signal. The input-output timing relationship of OLA is illustrated at a conceptual level in FIG. 3 for a speed factor of β=2.5. The analysis frame size SA is the product of the speed factor β and the synthesis frame size SS; that is, SA=β·SS, which is 2.5×SS in the example of FIG. 3 .
The input waveform is divided into blocks A, B, C, D, E, F, G, H, . . . , etc., as shown in FIG. 3 . Each of the waveform blocks has SS input samples. On a conceptual level, the operation of the OLA method is very simple. At a fixed interval, two adjacent blocks are taken from the input signal with the starting point of the two blocks being SA samples later than the starting point of the last two blocks taken. Each pair of input blocks is copied to the output time line in the manner shown in FIG. 3 . The dotted lines indicate how a pair of input blocks is copied to the output time line. Each new pair of blocks in the output is SS samples later than the last pair of blocks. Then, the second half of each pair of blocks (blocks B, D, F, H, J, . . . ) is multiplied by a “fade-out” window, which can be as simple as a ramp-down triangular window, and the first half of each pair of blocks except the very first pair (blocks C, E, G, I, . . . ) is multiplied by a “fade-in” window, which can be a ramp-up triangular window. After such windowing, for each time period of SS samples, the two windowed blocks that are vertically aligned in FIG. 3 are overlap-added. For example, block B is overlap-added with block C, and block D is overlap-added with block E, and so on. The resulting waveform of such overlap-add operation is the output signal of the OLA method.
By inspecting FIG. 3 , it should be obvious that an input signal sample located at the sample index of n×SA will appear at the sample index of n×SS in the OLA output signal before being overlap-added. Therefore, the time scale is compressed by a factor of SA/SS=β=2.5. In other words, the output signal is 2.5 times shorter and thus will play back at a speed that is 2.5 times faster than the normal playback rate if the sampling rate stays the same.
It should be noted that a speed factor of β=2.5 was intentionally selected for the example of FIG. 3 so that different pairs of input waveform blocks do not overlap each other. This is purely for convenience of illustration. In reality, the speed factor β can be any positive number. When β<2, there will be overlap between pairs of input blocks. For example, if β=1.5, then those input signal samples in the second half of block B will also be in the first half of block C because SA=1.5×SS in this case.
The purpose of the overlap-add operation is to achieve a gradual and smooth transition between two blocks of different waveforms. This operation can eliminate waveform discontinuity that would otherwise occur at the block boundaries.
Although the OLA method is very simple and it avoids waveform discontinuities, its fundamental flaw is that the input waveform is copied to the output time line and overlap-added at a rigid and fixed time interval, completely disregarding the properties of the two blocks of underlying waveforms that are being overlap-added. Without proper waveform alignment, the OLA method often leads to destructive interference between the two blocks of waveforms being overlap-added, and this causes fairly audible wobbling or tonal distortion.
2.3. Traditional SOLA Algorithm
Synchronized Overlap-Add (SOLA) solves the foregoing problem by copying the input waveform block to the output time line not at a fixed time interval like OLA, but at a location near where OLA would copy it to, with the optimal location (or optimal time shift from the OLA location) chosen to maximize some sort of waveform similarity measure between the two blocks of waveforms to be overlap-added. Since the two waveforms being overlap-added are maximally similar, destructive interference is greatly minimized, and the resulting output audio quality can be very high, especially for pure voice signals. This is especially true for speed factors close to 1, in which case the SOLA output voice signal sounds completely natural and essentially distortion-free.
In the context of FIG. 3 , the operation of SOLA can be explained as follows. When copying input waveform block C to the output time line, rather than placing the starting point of block C at sample index SS as in OLA, the traditional SOLA method would allow the starting point of block C to be in a range from sample index 0 to 2SS− that is, with a time shift between—SS and SS samples relative to the block C location of OLA. The optimal time shift is determined by maximizing a waveform similarity measure (or equivalently, minimizing a waveform difference measure) between the sliding block C and the waveform in blocks A and B from sample index 0 to 2SS. Similarly, when copying input block E to the output time line, block E is allowed to have a time shift between −SS and SS samples relative to the fixed block E location of OLA as shown in FIG. 3 . In other words, the starting point of block E will be somewhere between sample index SS and 3SS. Similarly, the starting point of block G will be somewhere between sample index 2SS and 4SS, and so on.
It should be noted that there exist many possible waveform similarity measures or waveform difference measures that can be used to judge the degree of similarity or difference between two pieces of waveforms. A common example of a waveform similarity measure is the so-called “normalized cross correlation”, which is defined in Section 3 later. Another example is just the plain cross-correlation without normalization. A common example of a waveform difference measure is the so-called Average Magnitude Difference Function (AMDF), which was often used in some of the early pitch extraction algorithms and is well-known by persons skilled in the art. By maximizing a waveform similarity measure, or equivalently, minimizing a waveform difference measure, one can find an optimal time shift that corresponds to maximum likeness or minimum difference between two pieces of waveforms, thus after such two pieces of waveforms are overlapped and added, it results in the minimum degree of destructive interference or partial waveform cancellation.
For convenience of discussion, in the rest of this document only normalized cross-correlation will be mentioned in describing example embodiments of the present invention. However, persons skilled in the art will readily appreciate that similar results and benefits may be obtained by simply substituting another waveform similarity measure for the normalized cross-correlation, or by replacing it with a waveform difference measure and then reversing the direction of optimization (from maximizing to minimizing). Thus, the description of normalized cross-correlation in this document should be regarded as just an example and is not limiting.
Some researchers of SOLA have noted that the same audio quality can be achieved by limiting the allowable time shift to be between 0 and SS samples rather than between −SS and SS samples. For example, rather than allowing the starting point of block C to be between sample index 0 and 2SS, it can be limited to be between sample index SS and 2SS. Similarly, the starting point of block E is limited to the range between sample index 2SS and 3SS. This cuts the complexity of optimal time shift search by half. Furthermore, it also allows earlier release of block A to be played out before starting the search of the optimal location for block C (and earlier release of the overlap-added version between block B and C before searching for the optimal location for block E, and so on). In a modified implementation of SOLA in accordance with an embodiment of the present invention, this change of limiting the time shift to one side has also been adopted.
In an embodiment of the present invention, another change was made from the traditional SOLA. In the traditional SOLA, as one slides block C toward the right direction in FIG. 3 , the overlapping portion between blocks B and C becomes progressively shorter until it reaches a length of only one sample. This will make the normalized cross-correlation increasingly unreliable as a waveform similarity measure. To overcome this problem, an additional block B′ of SS sample right after (to the right of) block B is included in order to maintain a constant length of overlapped portion with block C when one slides block C from a time shift of 0 to a time shift of SS samples. This is illustrated in FIG. 4 , again for the speed factor of β=2.5. To avoid confusion to the eyes, the dotted lines in FIG. 3 are not shown in FIG. 4 .
In FIG. 4 , above each block beneath the output time line, a horizontal double arrow indicates the allowable range for the starting point of that block, while the short upward arrow at the starting point of that block indicates the optimal location that maximizes a waveform similarity measure within that allowable range. Every waveform block in FIG. 4 has SS waveform samples.
The step-by-step operation of a modified SOLA algorithm in accordance with an embodiment of the present invention is now described with reference to FIG. 4 . At the start of the modified SOLA algorithm, the input waveform block A is copied to the output and released for playback. The input waveform blocks B and B′ are then copied to the output buffer. Next, the input waveform blocks C, D, and D′ are copied to the input buffer. Block C, which starts at input sample index SA, is then used as a template that slides in the allowable range in the output time line as indicated in FIG. 4 while the normalized cross-correlation is calculated. That is, initially block C coincides with block B, and the normalized cross-correlation value is calculated. Next, block C is shifted to the right by one sample to overlap with the last SS−1 samples of block B and the first sample of block B′, and normalized cross-correlation value of the two overlapped waveform segments is calculated, then block C is shifted to the right by another sample. This process continues until block C coincides with block B′, after which a total of SS+1 normalized cross-correlation values will have been calculated. The time shift corresponding to the maximum of these SS+1 normalized cross-correlation values is used as the final location of block C.
For convenience of description and without loss of generality, suppose that the optimal time shift for block C happens to be SS/2 samples, exactly half way in the middle of the allowable range as shown in FIG. 4 . Then, the next step is to apply a fade-out window to the second half of block B and the first half of block B′, apply a fade-in window to block C, and then overlap-add the two windowed waveform segments in the output buffer (which now contains blocks B and B′). After the overlap-add operation, the first SS samples of the output buffer, which correspond to the previous block B, are released to output for playback. Then, the second half of overlap-added samples, which is located from the (SS+1)th sample to the (SS+SS/2)th sample in the output buffer, is shifted by SS samples to the beginning portion, or the first quarter, of the output buffer. (This shifting operation can be avoided by using a circular buffer, as is well-known in the art, but here it will be described as a shifting operation for convenience of description.) Next, the remaining three-quarters of the output buffer are filled by copying the (3/2)×SS input signal samples immediately following block C. That is, the entire block D and the first half of block D′ are copied from the input buffer to fill the remaining portion of the output buffer. This means that the second half of block B′ that was originally in the output buffer will be overwritten by the first half of block D. This completes the modified SOLA processing associated with block C.
Next, the input buffer is filled with input waveform blocks E, F, and F′. Now block E replaces the role of block C in the algorithm description above, and the same operations applied to block C are now applied to block E. The only difference is that in general the optimal time shift is not necessarily SS/2 samples, but can be any integer between 0 and SS samples, and therefore the description of “first half” and “second half” above will now just be a proper portion determined by the optimal time shift. This process is then repeated for blocks G, H, and H′, blocks I, J, and J′, and so on.
2.4. Modified SOLA Algorithm in Accordance with Embodiments of the Present Invention
In a traditional SOLA approach, nearly all of the computational complexity is in the search of the optimal time shift based on the SS+1 normalized cross-correlation values. Each cross-correlation involves an inner product of two vectors with lengths of SS samples. As mentioned earlier, the complexity of traditional SOLA may be too high for a system having limited processing resources, and great reduction of the complexity may thus be needed for a practical implementation.
In accordance with an embodiment of the present invention, the complexity of SOLA can be reduced by roughly two orders of magnitude. The reduction is achieved by calculating the normalized cross-correlation values using a decimated (i.e. down-sampled) version of the output buffer and the input template block (blocks A, C, E, G and I in FIG. 4 ). Suppose the output buffer is decimated by a factor of 10, and the input template block is also decimated by a factor of 10. Then, when one searches for the optimal time shift in the decimated domain, one has about 10 times fewer normalized cross-correlation values to evaluate, and each cross-correlation has 10 times fewer samples involved in the inner product. Therefore, one can save the associated computational complexity by a factor of 10×10=100. The final optimal time shift is obtained by multiplying the optimal decimated time shift by the decimation factor of 10.
Of course, the resulting optimal time shift of the foregoing approach has only one-tenth the time resolution of SOLA. However, it has been observed that the output audio quality is not very sensitive to this loss of time resolution. In fact, in trying decimation factors from 2 all the way to 16, it has been observed in limited informal listening that the output quality did not change too much.
If one wished, one could perform a refinement time shift search in the undecimated time domain in the neighborhood of the coarser optimal time shift. However, this will significantly increase the computational complexity of the algorithm (easily double or triple), and the resulting audio quality improvement is not very noticeable. Therefore, it is not clear such a refinement search is worthwhile.
Another issue with a modified implementation of SOLA in accordance with the present invention is how the decimation is performed. Classic text-book examples teach that one needs to do proper lowpass filtering before down-sampling to avoid aliasing distortion. However, even with a highly efficient third-order elliptic filter, the lowpass filtering requires even more computational complexity than the normalized cross-correlation in the decimation-by-10 example above. It has been observed that direct decimation without lowpass filtering results in output audio quality that is just as good as with lowpass filtering. In fact, if one uses the average normalized cross-correlation as a quality measure for output audio quality, then direct decimation without lowpass filtering actually achieves slightly higher scores than the text-book example of lowpass filtering followed by decimation. For this reason, in a modified SOLA algorithm in accordance with an embodiment of the present invention, direct decimation is performed without lowpass filtering.
Another benefit of direct decimation without lowpass filtering is that the resulting algorithm can handle pure tone signals with tone frequency above half of the sampling rate of the decimated signal. If one implements a good lowpass filter with high attenuation in the stop band before one decimates, then such high-frequency tone signals will be mostly filtered out by the lowpass filter, and there will not be much left in the decimated signal for the search of the optimal time shift. Therefore, it is expected that applying lowpass filtering can cause significant problems for pure tone signals with tone frequency above half of the sampling rate of the decimated signal. In contrast, direct decimation will cause the high-frequency tones to be aliased back to the base band, and a SOLA algorithm with direct decimation without lowpass filtering works fine for the vast majority of the tone frequencies, all the way up to half the sampling rate of the original undecimated input signal. In fact, tests of such a direct-decimation modified SOLA algorithm have been performed with a sweeping tone signal that has the tone frequency sweeping very slowly from 0 to 22.05 kHz. It has been observed that the direct-decimation SOLA output tone signal is fine for almost all frequencies, except occasionally the output waveform envelope dipped a little bit when the tone frequency is an integer multiple of half of the sampling rate of the decimated signal. However, such magnitude dip does not happen for every integer multiple, but only occasionally for a small number of integer multiples of half of the sampling rate of the decimated signal.
3. Detailed Description of a Modified SOLA Algorithm In Accordance with an Embodiment of the Present Invention
There are many different ways to implement the input/output buffering scheme of a modified SOLA algorithm in accordance with the present invention. Some are simple and easy to understand but require more memory, while others are more efficient in memory usage but require more complicated program control and thus are more difficult to understand. In what follows below, a detailed, step-by-step description of a modified SOLA algorithm in accordance with an embodiment of the present invention is provided using the simplest I/O buffering scheme that is the easiest to understand but also uses the greatest amount of memory (e.g., data RAM). More memory efficient I/O buffering schemes will be described in the next section. Understanding the simple I/O buffering scheme in this section will be helpful for the understanding of the memory-efficient schemes in the next section.
In this simple I/O buffering scheme, the input buffer x=[x( 1 ), x( 2 ), . . . x(LX)] is a vector with LX=3×SS samples, and the output buffer y=[y( 1 ), y( 2 ), . . . , y(LY)] is another vector with LY=2×SS samples, in correspondence with what is shown in FIG. 4 . For ease of description, the following description will make use of the standard Matlab vector index notation, where x(j:k) means a vector containing the j-th element through the k-th element of the x array. Specifically, x(j:k)=[x(j), x(j+1), x(j+2), . . . , x(k−1), x(k)]. Also, for convenience, all algorithm description below assumes linear buffers with sample shifting. However, those skilled in the art will know that they can avoid the sample shifting operations by implementing equivalent operations using circular buffers. A modified SOLA algorithm in accordance with an embodiment of the present invention is now described below, wherein each step is represented in flowchart 500 of FIG. 5 .
Algorithm A:
1. Initialization (step 502 ): At the start of the modified SOLA processing of an input audio file of PCM samples, the input buffer x array is filled with the first 3×SS samples of the input audio file (blocks A, B, and B′ in FIG. 4 ). The first SS samples of the input buffer (block A in FIG. 4 ), or x(1:SS), are released as output samples for play back. The last 2×SS samples of the input buffer (blocks B and B′) are copied to the output buffer, so y=x(SS+1:3×SS). The algorithm will enter a loop starting from the next step.
2. Update the input buffer (step 504 ): If SA<LX, that is, if the speed factor β=SA/SS<3, shift the input buffer x by SA samples, i.e., x(1:LX−SA)=x(SA+1:LX), and then fill the rest of the input buffer x(LX−SA+1:LX) by SA new input audio PCM samples from the input audio file. If SA≧LX, that is, if the speed factor β=SA/SS≧3, then fill the entire input buffer x with input signal samples that are SA samples later than the last set of samples stored in the input buffer. (The input buffer now contains input blocks C, D, D′, or E, F, F′, etc. in FIG. 4 .)
3. Decimate the input template and output buffer (step 506 ): The input template used for optimal time shift search is the first SS samples of the input buffer, or x(1:SS), which correspond to the blocks C, E, G, I, etc. in FIG. 4 . It is directly decimated to get the decimated input template xd(1:SSD)=[x(DECF), x(2×DECF), x(3×DECF), . . . , x(SSD×DECF)], where DECF is the decimation factor, and SSD is synthesis frame size in the decimated signal domain. Normally SS=SSD×DECF. Similarly, the output buffer is also decimated to get yd(1:2×SSD)=[y(DECF), y(2×DECF), y(3×DECF), y(2×SSD×DECF)]. Note that if the memory size is really constrained, one does not need to explicitly set aside memory for the xd and yd arrays when searching for the optimal time shift in the next step; one can directly index the x and y arrays using indices that are multiples of DECF, perhaps at the cost of increased number of instruction cycles used.
4. Search for optimal time shift in decimated domain between 0 and SSD (step 508 ): For a given time shift k, the waveform similarity measure is the normalized cross-correlation defined as
R ( k ) = ∑ n = 1 SSD xd ( n ) y d ( n + k ) ∑ n = 1 SSd xd 2 ( n ) ∑ n = 1 SSD y d 2 ( n + k ) ,
where R(k) can be either positive or negative. To avoid the square-root operation, it is noted that finding the k that maximizes R(k) is equivalent to finding the k that maximizes
Q ( k ) = sign ( R ( k ) ) × R 2 ( k ) = sign ( ∑ n = 1 SSD xd ( n ) y d ( n + k ) ) × [ ∑ n = 1 SSD xd ( n ) y d ( n + k ) ] 2 ∑ n = 1 SSD xd 2 ( n ) ∑ n = 1 SSD y d 2 ( n + k ) where sign ( x ) = { 1 , if x ≥ 0 - 1 , if x < 0 .
Furthermore, since
∑ n = 1 SSD xd 2 ( n ) ,
which is the energy of the decimated input template, is independent of the time shift k, finding k that maximizes Q(k) is also equivalent to finding k that maximizes
P ( k ) = sign ( ∑ n = 1 SSD xd ( n ) y d ( n + k ) ) × [ ∑ n = 1 SSD xd ( n ) y d ( n + k ) ] 2 ∑ n = 1 SSD y d 2 ( n + k ) = c ( k ) e ( k ) , where c ( k ) = sign ( ∑ n = 1 SSD xd ( n ) y d ( n + k ) ) [ ∑ n = 1 SSD xd ( n ) y d ( n + k ) ] 2 and e ( k ) = ∑ n = 1 SSD y d 2 ( n + k ) .
To avoid the division operation in
which may be very inefficient in a DSP core, it is further noted that finding the k between 0 and SSD that maximizes P(k) involves making SSD comparison tests in the form of testing whether P(k)>P(j), or whether
c ( k ) e ( k ) > c ( j ) e ( j ) ,
but this is equivalent to testing whether c(k)e(j)>c(j)e(k). Thus, the so-called “cross-multiply” technique may be used in an embodiment of the present invention to avoid the division operation. In addition, an embodiment of the present invention may calculate the energy term e(k) recursively to save computation. This is achieved by first calculating
e ( 0 ) = ∑ n = 1 SSD y d 2 ( n )
using SSD multiply-accumulate (MAC) operations. Then, for k from 1, 2, . . . to SSD, each new e(k) is recursively calculated as e(k)=e(k−1)−yd 2 (k)+yd 2 (SSD+k) using only two MAC operations. With all this algorithm background introduced above, the algorithm to search for the optimal time shift in the decimated signal domain can now be described as follows.
Calculate
Ey
=
∑
n
=
1
SSD
y
d
2
(
n
)
4.b.
Calculate
cor
=
∑
n
=
1
SSD
xd
(
n
)
y
d
(
n
)
4.c. If cor>0, set cor2opt=cor×cor; otherwise,
set cor2opt=−cor×cor.
4.d. Set Eyopt=Ey and set koptd=0.
4.e. For k from 1, 2, 3, . . . to SSD, do the following indented part:
4.e.i. Calculate
Ey=Ey−yd ( k )× yd ( k )+ yd ( SSD+k )× yd ( SSD+k ).
4.e.ii.
Calculate
cor
=
∑
n
=
1
SSD
xd
(
n
)
y
d
(
n
+
k
)
.
4.e.iii. If cor>0, set cor2=cor×cor; otherwise,
set cor2=−cor×cor.
4.e.iv. If cor2×Eyopt>cor2opt×Ey, then reset koptd=k,
Eyopt=Ey, and cor2opt=cor2
4.f When the algorithm execution reaches here, the final koptd is the optimal time shift in the decimated signal domain.
5. Calculate optimal time shift in undecimated domain (step 510 ): The optimal time shift in the undecimated signal domain is calculated as kopt=DECF×koptd.
6. Perform overlap-add operation (step 512 ): Where the algorithm is implemented in software, if the program size is not constrained, it is recommended to use raised cosine as the fade-out and fade-in windows: Fade-out window:
w o ( n ) = 0.5 × [ 1 + cos ( n π SS + 1 ) ] , for n = 1 , 2 , 3 , … , SS .
Fade-in window: w i (n)=1−w o (n), for n=1, 2, 3, . . . , SS. Note that only one of the two windows above need to be stored as a data table. The other one can be obtained by indexing the first table from the other end in the opposite direction. If it is desirable not to store any of such windows, then we can use triangular windows and calculate the window values “on-the-fly” by adding a constant term with each new sample. The overlap-add operation is performed “in place” by overwriting the portion of the output buffer with the index range of 1+kopt to SS+kopt, as described below:
For n from 1, 2, 3, . . . to SS, do the next indented line:
y ( n+kopt )= w o ( n ) y ( n+kopt )+ w i ( n )×( n )
7. Release output samples for play back (step 514 ): When the algorithm execution reaches here, the current frame of output samples stored in y(1:SS) are released for playback. These output samples should be copied to another output array before they are overwritten in the next step.
8. Update the output buffer (step 516 ): To prepare for the next frame, the output buffer is updated as follows.
8a. If kopt≠0, shift the overlap-added portion of the output buffer that has not been released for playback yet by SS samples. That is, y(1:kopt)=y(SS+1:SS+kopt). 8b. Fill the rest of the output buffer with new input samples after the input template in the input buffer. That is,
y ( kopt +1:2 ×SS )= x ( SS+ 1:3 ×SS−kopt ).
9. Go back to Step 2 above to process next frame.
4. More Memory-Efficient Input/Output Buffering Schemes in Accordance with Embodiments of the Present Invention
The modified SOLA algorithm described in the previous section can be modified to use less memory in the input/output buffers at the cost of more complicated program control. In one version of such memory-efficient buffering schemes, the length of the input buffer can be shorter than the 3×SS samples described in the last section. The key observation that enables such a reduction is that when SA is greater than the overlap-add length, then after the overlap-add operation, the first SS samples of the input buffer are no longer needed. Therefore, rather than updating the entire output buffer in one shot in Step 8 and then shifting the input buffer in Step 2 as described in the previous section, an embodiment of the present invention can update only the first portion of the output buffer, then shift the input buffer and read new samples into the input buffer, and then complete the update of the second portion of the output buffer, possibly using new input samples just read in. This allows a shorter input buffer to be used. This basic idea is simple, but actual implementation is tricky because depending on the relationship of certain SOLA parameters, the copying operations may “run off the edge” of a buffer, and therefore requires careful checking with if statements.
In the following memory-efficient buffering scheme, a rigid requirement in the previous algorithm version described in Section 3 has been relaxed—namely, the requirement that the synthesis frame size, the overlap-add length, and the length of optimal time shift search range must all be identical. Such a constraint limits the flexibility of the design and tuning of the algorithm. It is desirable to be able to adjust these three parameters independently. This goal is achieved with the more memory-efficient algorithm described below. The symbol “SS” is still used for the synthesis frame size as before. However, to distinguish the other two parameters, the symbol “L” is used for the length of the optimal time shift search range, and the symbol “WS” for the “window size” of the sliding window for cross-correlation calculation, which is also the overlap-add window size. A minor constraint is maintained of requiring WS≧SS.
This more memory-efficient algorithm is now described below. At a high level, the steps performed are illustrated in flowchart 600 of FIG. 6 . However, the details concerning how some of the steps are performed are different than those described above with respect to Algorithm A. Where the algorithms are similar, some explanatory text has been omitted in the description of this memory-efficient version.
Algorithm B:
1. Initialization (step 602 ): Set N=WS+L+SS−SA. The input buffer size is LX=N if SA<N and is LX=SA if SA≧N. The output buffer size is LY=WS+L. At the start of the modified SOLA processing of an input audio file of PCM samples, the input buffer x array is filled with the first LX samples of the input audio file. The first SS samples of the input buffer, or x(1:SS), are released as output samples for play back. Then, the output buffer is prepared for entering the loop below as follows:
If SA<WS, do the next two indented lines:
Update the initial portion of the output buffer as
y (1 :WS−SS )= x ( SS +1 :WS )
Otherwise, do the following indented section:
If SA<N, do the next two indented lines:
Update the initial portion of the output buffer as
y (1 :SA−SS )= x ( SS +1 :SA ).
Otherwise (if SA≧N), do the next two indented lines:
If N>0, set y (1 :SA−SS )= x ( SS +1 :SA );
Otherwise, set y (1 :LY )= x ( SS +1 :LY+SS ).
After this initialization, the algorithm enters a loop starting from the next step.
2. Update the input buffer and copy appropriate portion of input buffer to the tail portion of the output buffer (step 604 ): If SA<LX, shift the input buffer x by SA samples, i.e., x(1:LX−SA)=x(SA+1:LX), and then fill the rest of the input buffer x(LX−SA+1:LX) by SA new input audio PCM samples from the input audio file. If SA≧LX, then fill the entire input buffer x with input signal samples that are SA samples later than the last set of samples stored in the input buffer. This completes the input buffer update. Next, an appropriate portion of this updated input buffer is copied to the tail portion of the output buffer as described below.
If SA<WS, do the next two indented lines:
Update the tail portion of the output buffer as
y ( WS−SS+kopt +1 :LY )= x ( WS−SA +1 :LX−kopt )
Otherwise, if N−kopt>0, do the next two indented lines:
Update the tail portion of the output buffer as
y ( SA−SS+kopt +1 :LY )= x (1 :N−kopt )
3. Decimate the input template and output buffer (step 606 ): The input template used for optimal time shift search is the first SS samples of the input buffer, or x(1:SS). This input template is directly decimated to get the decimated input template xd(1:SSD)=[x(DECF), x(2×DECF), x(3×DECF), . . . , x(SSD×DECF)], where DECF is the decimation factor, and SSD is synthesis frame size in the decimated signal domain. Normally SS=SSD×DECF. Similarly, the output buffer is also decimated to get yd(1:2×SSD)=[y(DECF), y(2×DECF), y(3×DECF), . . . , y(2×SSD×DECF)]. Note that if the memory size is really constrained, one does not need to explicitly set aside memory for the xd and yd arrays when searching for the optimal time shift in the next step; one can directly index the x and y arrays using indices that are multiples of DECF, perhaps at the cost of increased number of instruction cycles used.
4. Search for optimal time shift in decimated domain between 0 and SSD (step 608 ): For a given time shift k, the waveform similarity measure is the normalized cross-correlation defined as
R ( k ) = ∑ n = 1 SSD xd ( n ) yd ( n + k ) ∑ n = 1 SSD xd 2 ( n ) ∑ n = 1 SSD yd 2 ( n + k ) ,
where R(k) can be either positive or negative. To avoid the square-root operation, it is noted that finding the k that maximizes R(k) is equivalent to finding the k that maximizes
Q ( k ) = sign ( R ( k ) ) × R 2 ( k ) = sign ( ∑ n = 1 SSD xd ( n ) yd ( n + k ) ) × [ ∑ n = 1 SSD xd ( n ) yd ( n + k ) ] 2 ∑ n = 1 SSD xd 2 ( n ) ∑ n = 1 SSD yd 2 ( n + k ) where sign ( x ) = { 1 , if x ≥ 0 - 1 , if x < 0 .
Furthermore, since
∑ n = 1 SSD xd 2 ( n ) ,
which is the energy of the decimated input template, is independent of the time shift k, finding k that maximizes Q(k) is also equivalent to finding k that maximizes
P ( k ) = sign ( ∑ n = 1 SSD xd ( n ) yd ( n + k ) ) × [ ∑ n = 1 SSD xd ( n ) yd ( n + k ) ] 2 ∑ n = 1 SSD yd 2 ( n + k ) = c ( k ) e ( k ) ,
where c ( k ) = sign ( ∑ n = 1 SSD xd ( n ) yd ( n + k ) ) [ ∑ n = 1 SSD xd ( n ) yd ( n + k ) ] 2 and e ( k ) = ∑ n = 1 SSD yd 2 ( n + k ) .
To avoid the division operation in
c ( k ) e ( k ) ,
which may be very inefficient in a DSP core, it is further noted that finding the k between 0 and SSD that maximizes P(k) involves making SSD comparison tests in the form of testing whether P(k)>P(j), or whether
c ( k ) e ( k ) > c ( j ) e ( j ) ,
but this is equivalent to testing whether c(k)e(j)>c(j)e(k). Thus, the so-called “cross-multiply” technique may be used in an embodiment of the present invention to avoid the division operation. In addition, an embodiment of the present invention may calculate the energy term e(k) recursively to save computation. This is achieved by first calculating
e ( 0 ) = ∑ n = 1 SSD yd 2 ( n )
using SSD multiply-accumulate (MAC) operations. Then, for k from 1, 2, . . . to SSD, each new e(k) is recursively calculated as e(k)=e(k−1)−yd 2 (k)+yd 2 (SSD+k) using only two MAC operations. With all this algorithm background introduced above, the algorithm to search for the optimal time shift in the decimated signal domain can now be described as follows.
4.
a
.
Calculate
Ey
=
∑
n
=
1
SSD
yd
2
(
n
)
4.
b
.
Calculate
cor
=
∑
n
=
1
SSD
x
d
(
n
)
yd
(
n
)
4.c. If cor>0, set cor2opt=cor×cor; otherwise,
set cor2opt=−cor×cor.
4.d. Set Eyopt=Ey and set koptd=0.
4.e. For k from 1, 2, 3, . . . to SSD, do the following indented part:
4.e.i. Calculate
Ey=Ey−yd ( k )× yd ( k )+ yd ( SSD+k )× yd ( SSD+k ).
4.
e
.
ii
.
Calculate
cor
=
∑
n
=
1
SSD
xd
(
n
)
yd
(
n
+
k
)
.
4.e.iii. If cor>0, set cor2=cor×cor; otherwise,
set cor2=−cor×cor.
4.e.iv. If cor2×Eyopt>cor2opt×Ey, then reset koptd=k,
Eyopt=Ey, and cor2opt=cor2
4.f When the algorithm execution reaches here, the final koptd is the optimal time shift in the decimated signal domain.
5. Calculate optimal time shift in undecimated domain (step 610 ): The optimal time shift in the undecimated signal domain is calculated as kopt=DECF×koptd.
6. Perform overlap-add operation (step 612 ): If the program size is not constrained, using raised cosine as the fade-out and fade-in windows is recommended:
Fade-out window:
w o ( n ) = 0.5 × [ 1 + cos ( n π SS + 1 ) ] , for n = 1 , 2 , 3 , … , SS .
Fade-in window: w i (n)=1−w o (n), for n=1, 2, 3, . . . , SS.
Note that only one of the two windows above need to be stored in as a data table. The other one can be obtained by indexing the first table from the other end in the opposite direction. If it is desirable not to store any of such windows, then we can use triangular windows and calculate the window values “on-the-fly” by adding a constant term with each new sample. The overlap-add operation is performed “in place” by overwriting the portion of the output buffer with the index range of 1+kopt to SS+kopt, as described below:
For n from 1, 2, 3, . . . to SS, do the next indented line:
y(n+kopt)=w o (n)y(n+kopt)+w i (n)x(n).
7. Release output samples for play back (step 614 ): When the algorithm execution reaches here, the current frame of output samples stored in y(1:SS) are released for playback. These output samples should be copied to another output array before they are overwritten in the next step.
8. Update the output buffer (step 616 ): To prepare for the next frame, the output buffer is updated as follows.
8a. Shift the portion of the output buffer up to the end of the overlap-add period as follows.
y (1 :WS−SS+kopt )= y ( SS +1 :WS+kopt ).
8b. If SA≧WS, further update the portion of the output buffer right after the portion updated in step 8a above by copying the appropriate portion of the input buffer as follows.
If N−kopt>0, do the next two indented lines:
Update portion of the output buffer as
y ( WS−SS+kopt +1 :SA−SS+kopt )= x ( WS +1 :SA ).
Otherwise, do the next two indented lines:
Update portion of the output buffer as
y ( WS−SS+kopt +1 :LY )= x ( WS +1 :LY+SS−kopt ).
9. Go back to Step 2 above to process nextframe.
5. The Use of Circular Buffers to Eliminate Shifting Operations
As can be seen in Steps 2 and 8 of the algorithms in Sections 3 and 4 above, one of the main tasks in updating the input buffer and the output buffer is to shift a large portion of the older samples by a fixed number of samples. One example is the input buffer shifting operation of x(1:LX−SA)=x(SA+1:LX) in Step 2 in Section 4 above.
When the input and output buffers are implemented as linear buffers, such shifting operations involve data copying and can take a large number of processor cycles. However, most modern digital signal processors (DSPs), including the ZSP400, have built-in hardware to accelerate the “modulo” indexing required to support a so-called “circular buffer”. As will be appreciated by persons skilled in the art, most DSPs today can perform modulo indexing without incurring cycle overhead. When such DSPs are used to implement circular buffers, then the sample shifting operations mentioned above can be completely eliminated, thus saving a considerable number of DSP instruction cycles.
The way a circular buffer works should be well known to those skilled in the art. However, an explanation is provided below for the sake of completeness. Take the input buffer x(1:LX) as an example. A linear buffer is just a linear array of LX samples. A circular buffer is also an array of LX samples. However, instead of having a definite beginning x(1) and a definite end x(LX) as in the linear buffer, a circular buffer is like a linear buffer that is curled around to make a circle, with x(LX) “bent” and placed right next to x(1). The way a circular buffer works is that each time this circular buffer array x(:) is indexed, the index is always put through a “modulo LX” operations, where LX is the length of the circular buffer. There is also a variable pointer that points to the “beginning” of the circular buffer, where the beginning changes with each new frame. For each new frame, this pointer is advanced by N samples, where N is the frame size.
A more specific example will help to understand how a circular buffer works. In Step 2 above, with a linear buffer, x(SA+1:LX) is copied to x(1:LX−SA). In other words, the last LX−SA samples are shifted in the linear buffer by SA samples so that they occupy the first LX−SA samples. That requires LX−SA memory read operations and LX−SA memory write operations. Then, the last SA samples of the linear buffer, or x(LX−SA+1:LX), are filled by SA new input audio PCM samples from the input audio file. In contrast, when a circular buffer is used, the LX−SA read operations and LX−SA write operations can all be avoided. The pointer p (that points to the “beginning” of the circular buffer) is simply incremented by SA, modulo LX; that is, p=modulo(p+SA, LX). This achieves the equivalent of shifting those last LX−SA samples of the frame by SA samples. Then, based on this incremented new pointer value p (and the corresponding new beginning and end of the circular buffer), the last SA samples of the “current” circular buffer are simply filled by SA new input audio PCM samples from the input audio file. Again, when the circular buffer is indexed to copy these SA new input samples, the index needs to be go through the modulo LX operation.
A DSP such as the ZSP400 can support two independent circular buffers in parallel with zero overhead for the modulo indexing. This is sufficient for the input buffer and the output buffer of the SOLA algorithms presented above (both Algorithm A and Algorithm B). Therefore, all the sample shifting operations in Algorithms A and B can be completely avoided if the input and output buffers are implemented as circular buffers using the ZSP400's built-in support for circular buffer. This will save a large number of ZSP400 instruction cycles.
6. Example Configuration for AC-3 at 44.1 kHz and 1.2× Speed
The modified SOLA algorithm described above does not take into account the frame size of the audio codec. It simply assumes that the input audio PCM samples are available as a continuous stream. In reality, typically only compressed audio bit-stream data frames are stored. Thus, in accordance with an embodiment of the present invention, an interface routine is provided to schedule the required audio decoding operation to ensure that the modified SOLA algorithm will have the necessary input audio PCM samples available when it needs to read such audio samples.
From this perspective, it may simplify the task of this interface routine if either the SOLA input frame size SA or the output frame size SS is chosen to be an integer sub-multiple or integer multiple of the frame size of the audio codec. However, doing so means one cannot use the same SA or SS values for all audio codecs, since different audio codecs have different frame sizes. Even for a given audio codec and a given set of SA and SS values, when the sampling rate changes, the same SA and SS correspond to different lengths in terms of milliseconds.
Consequently, the optimal set of SOLA parameters (SA, SS, etc.) will be different for different audio codecs, different sampling rates, and even different speed factors. This is handled in an embodiment of the present invention by carefully designing the SOLA parameter set off-line for each combination of audio codec, sampling rate, and speed factor, storing all such parameter sets in program memory, and then when the modified SOLA algorithm is executed, reading and using the correct set of parameters based on the audio codec, sampling rate, and speed factor. With three or four audio codecs (AC-3, MP3, AAC, and WMA), three sampling rates (48, 44.1, and 32 kHz), and several speed factors, there is a large number of possible combinations.
By way of example, a SOLA parameter set is provided for AC-3 at 44.1 sampling and a speed factor of 1.2. In this example configuration, the analysis frame size SA is half of the AC-3 frame size of 1536. In other words, SA=1536/2=768 samples. Since the speed factor is 1.2, the synthesis frame size is SS=SA/1.2=640 samples. This corresponds to 640/44.1=14.51 ms, which is not too far from a typical default simulation value of 15 ms. One can use a decimation factor of DECF=8, then the synthesis frame size in the decimated domain is 640/8=80 samples.
Based on this set of parameters, assuming decimation was not performed (i.e. if DECF=1), a Matlab simulation code reports that the resulting modified SOLA algorithm had a computational complexity of 57.33 MFLOPS (Mega Floating-point Operations Per Second). With 8 to 1 decimation, the same Matlab code reported the corresponding modified SOLA algorithm had a complexity of 1.11 MFLOPS. However, it was discovered that Matlab counts a MAC operation as two floating-point operations rather than one. If one counts MAC operations, such a modified SOLA algorithm will take about 0.55 million MAC operations per second. It is estimated that such a modified SOLA algorithm can be implemented in ZSP400 core in about 2 MIPS or so.
For a mono audio channel, with Algorithm A presented in Section 3 above, the input buffer x has 3×SS=3×640=1920 words, and the output buffer y has 2×SS=2×640=1280 words, for a total of 3200 words. If separate decimated xd and yd arrays are used as described in Section 3 (rather than directly indexing x and y with “index jump” of 8), then that requires additional 80+2×80=240 words, for a total of 3440 words. On the other hand, with Algorithm B presented in Section 4 above, suppose the parameters are selected such that WS=L=SS, then the input buffer x has LX=WS+L+SS−SA=1.8 SS=1152 words. This is a saving of 1920−1152=768 words. The memory sizes for the output buffer has LX=WS+L+SS−SA=1.8 SS=1152 words. This is a saving of 1920−1152=768 words. The memory sizes for the output buffer y and decimated xd and yd arrays are the same as in Algorithm A.
7. Applying TSM to Stereo and Multi-Channel Audio
When applying a TSM algorithm to a stereo audio signal or even an audio signal with more than two channels, an issue arises: if TSM is applied to each channel independently, in general the optimal time shift will be different for different channels. This will alter the phase relationship between the audio signals in different channels, which results in greatly distorted stereo image or sound stage in general. This problem is inherent to any TSM algorithm, be it traditional SOLA, the modified SOLA algorithm described herein, or anything else.
One solution to this problem is to down-mix all the audio channels to a single mixed-down mono channel. Then, traditional or modified SOLA is applied to this mixed-down mono signal to derive the optimal time shift for each SOLA frame. This single optimal time shift is then applied to all audio channels. Since the audio signals in all audio channels are time-shifted by the same amount, the phase relationship between them is preserved, and the stereo image or sound stage is kept intact.
8. Possibilities for Further Complexity Reduction
If for any reason it is desirable to reduce the computational complexity of the modified SOLA algorithm even further, it is possible to integrate some of the prior-art SOLA complexity reduction techniques into the modified SOLA approach described herein. For example, the EM-TSM and MEM-TSM algorithms described in the following references can easily be applied to the decimated signal domain to further reduce the complexity of the modified SOLA algorithm described herein: J. W. C. Wong, O. C. Au, and P. H. W. Wong, “Fast time scale modification using envelope-matching technique (EM-TSM),” Proceedings of IEEE International Symposium on Circuits and Systems , Vol. 5, pp.550-553, May 1998, and P. H. W. Wong and O. C. Au, “Fast SOLA-based time scale modification using modified envelope matching,” Proceedings of 2002 IEEE International Conference on Acoustic, Speech, and Signal Processing , pp. 3188-3191, May 2002. Both of these references are incorporated by reference herein in their entirety.
9. Example Computer System Implementation
The following description of a general purpose computer system is provided for completeness. The present invention can be implemented in hardware, or as a combination of software and hardware. Consequently, the invention may be implemented in the environment of a computer system or other processing system. An example of such a computer system 700 is shown in FIG. 7 . In the present invention, all of the signal processing blocks depicted in FIGS. 1 and 2 , for example, can execute on one or more distinct computer systems 700 , to implement the various methods of the present invention. The computer system 700 includes one or more processors, such as processor 704 . Processor 704 can be a special purpose or a general purpose digital signal processor. The processor 704 is connected to a communication infrastructure 706 (for example, a bus or network). Various software implementations are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person skilled in the art how to implement the invention using other computer systems and/or computer architectures.
Computer system 700 also includes a main memory 705 , preferably random access memory (RAM), and may also include a secondary memory 710 . The secondary memory 710 may include, for example, a hard disk drive 712 and/or a removable storage drive 714 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 714 reads from and/or writes to a removable storage unit 715 in a well known manner. Removable storage unit 715 , represents a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 714 . As will be appreciated, the removable storage unit 715 includes a computer usable storage medium having stored therein computer software and/or data.
In alternative implementations, secondary memory 710 may include other similar means for allowing computer programs or other instructions to be loaded into computer system 700 . Such means may include, for example, a removable storage unit 722 and an interface 720 . Examples of such means may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units 722 and interfaces 720 which allow software and data to be transferred from the removable storage unit 722 to computer system 700 .
Computer system 700 may also include a communications interface 724 . Communications interface 724 allows software and data to be transferred between computer system 700 and external devices. Examples of communications interface 724 may include a modem, a network interface (such as an Ethernet card), a communications port, a PCMCIA slot and card, etc. Software and data transferred via communications interface 724 are in the form of signals which may be electronic, electromagnetic, optical or other signals capable of being received by communications interface 724 . These signals are provided to communications interface 724 via a communications path 726 . Communications path 726 carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link and other communications channels. Examples of signals that may be transferred over interface 724 include: signals and/or parameters to be coded and/or decoded such as speech and/or audio signals and bit stream representations of such signals; any signals/parameters resulting from the encoding and decoding of speech and/or audio signals; signals not related to speech and/or audio signals that are to be processed using the techniques described herein.
In this document, the terms “computer program medium,” “computer program product” and “computer usable medium” are used to generally refer to media such as removable storage unit 718 , removable storage unit 722 , a hard disk installed in hard disk drive 712 , and signals carried over communications path 726 . These computer program products are means for providing software to computer system 700 .
Computer programs (also called computer control logic) are stored in main memory 705 and/or secondary memory 710 . Also, decoded speech segments, filtered speech segments, filter parameters such as filter coefficients and gains, and so on, may all be stored in the above-mentioned memories. Computer programs may also be received via communications interface 724 . Such computer programs, when executed, enable the computer system 700 to implement the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor 704 to implement the processes of the present invention, such as methods in accordance with flowchart 500 of FIG. 5 and flowchart 600 of FIG. 6 , for example. Accordingly, such computer programs represent controllers of the computer system 700 . Where the invention is implemented using software, the software may be stored in a computer program product and loaded into computer system 700 using removable storage drive 714 , hard drive 712 or communications interface 724 .
In another embodiment, features of the invention are implemented primarily in hardware using, for example, hardware components such as application specific integrated circuits (ASICs) and gate arrays. Implementation of a hardware state machine so as to perform the functions described herein will also be apparent to persons skilled in the art.
10. Conclusion
The foregoing provided a detailed description of a modified SOLA algorithm in accordance with an embodiment of the present invention that produces fairly good output audio quality with a very low complexity. This modified SOLA algorithm achieves complexity reduction by performing the maximization of normalized cross-correlation using decimated signals. Many related issues have been discussed, and an example configuration of the modified SOLA algorithm for AC-3 at 44.1 kHz was given. With its good audio quality and low complexity, this modified SOLA algorithm is well-suited for use in audio speed up application for PVRs.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be understood by those skilled in the relevant art(s) that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. Accordingly, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A high-quality, low-complexity audio time scale modification (TSM) algorithm useful in speeding up or slowing down the playback of an encoded audio signal without changing the pitch or timbre of the audio signal. The TSM algorithm uses a modified synchronized overlap-add (SOLA) algorithm that maintains a roughly constant computational complexity regardless of the TSM speed factor and that performs most of the required SOLA computation using decimated signals, thereby reducing computational complexity by approximately two orders of magnitude. | 6 |
CROSS REFERENCE TO PRIOR APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 09/363,522 filed Jul. 29, 1999, now abandoned.
FIELD OF THE INVENTION
The invention relates to locking devices, and more particularly to locking devices for use with network interface devices (NIDs).
BACKGROUND OF THE INVENTION
Network interface devices (NIDs) or Network Interface Units (NIUs) house telephone line junctions and terminals. As used herein, the terms NID and NIU are interchangeable. The NID may provide either residential or commercial line access to one or more subscribers. The NID is typically placed between the subscriber's wiring and the service provider's subscriber loop.
Typically, the NID is sectioned for separate subscriber and service provider access. Each subscriber line terminal is typically covered by a hinged plate. Subscribers or service providers can usually access their individual lines in the compartment by lifting the plate, thereby exposing the subscriber line terminal. In many configurations, the compartment for a loop junction is limited to service provider access.
In most NID configurations, the individual subscriber line access cover plate is designed to be readily accessed. The line access covers are typically one inch wide and two inches in length, although there are known variations to these designs. Many configurations of these covers comprise a slot through which an apertured flange fixed to the NID housing may pass. A subscriber may place a small padlock through the aperture in the flange to prevent the cover from being lifted.
Unfortunately, present NID designs which enable easy access by subscribers and service providers, also permit access by unauthorized persons. The relatively small sized padlocks used for this application are known to have poor tamper-resistant characteristics. Additionally, due to the size of the cover, small padlocks must be used which are often difficult to use given dexterity limitations of individuals and/or the environmental conditions (i.e. poor lighting) at the NID. Even expensive small locks having improved tamper-resistant features also present similar problems. Additional problems result when a subscriber breaks a key in the lock or is unable to use the key provided with the lock due to the poor quality of the lock and key assembly. Further, larger locks, such as those having a combination or traditionally-sized keys, are typically not an option due to the size and physical limitations of the NID enclosure.
Consequently, line access in NIDs remains relatively poorly secured thereby exposing the subscriber to potential costs related to repair, theft and damage, particularly for NIDs accommodating numerous subscriber junctions.
Accordingly, there exists a need to economically and simply secure line access in NID configurations, and the like. There exists a need to provide a tamper-resistant solution that may be used in a relatively small area. There further exists a need for a device which is easily secured and removed by an authorized user of an existing NID cover configuration without affecting the operation of neighboring subscriber covers and/or accesses. Additionally, there exists a need to provide a device that locks a subscriber's line access cover uniquely from other accesses on the same NID, thereby preventing one subscriber from accessing another's line on the same NID.
SUMMARY OF THE INVENTION
Embodiments of the invention provide a locking device that may be used to prevent a subscriber from accessing another subscriber's line on the same NID.
The locking device includes a slotted cylinder having a first end, a second end and a first slot. The first slot has a distal end and a proximate end. The slot's proximate end coincides with the cylinder's first end and extends from the first cylinder end longitudinally and partially toward the second cylinder end. The cylinder has a second slot extending from, and opened to, the first slot distal end at an angle to the first slot. The cylinder has a resistance component contained in the cylinder at its second end. A key, mateable with the slotted cylinder, has a shaft with a key head at the first end of the shaft. A flange extends from and at an angle to a second end of the shaft. The key head has a cavity therein. The device also includes a key tool which is mateable with the key head cavity. The key may be inserted into the slotted cylinder and turned to lock it therein. The key tool is used to release the key from the slotted cylinder.
A cylindrical sleeve may be utilized for additional security. The sleeve has a first end, second end, first inner diameter, second inner diameter, and a third inner diameter. The first inner diameter is larger than the outer diameter of the slotted cylinder so that the slotted cylinder may fit in the sleeve. The first inner diameter extends from the first sleeve and to a length corresponding at least to the length of the slotted portion and the slotted cylinder. The sleeve's second diameter is larger than the key head so that the key head may fit at least partially within the sleeve. The second inner diameter extends from the second sleeve end to a length of at least about the key head length. The third inner diameter is positioned between the first inner diameter and the second inner diameter. The third inner diameter is larger than the key shaft diameter and smaller than the key head so that the sleeve cannot pass over the key head. A slot extending the length of the third inner diameter section and partially into the cylinder wall accommodates the key flange when the key is placed in the sleeve.
By use of different key head cavity shapes each subscriber may only access their own line in a NID.
DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read with the accompanying drawings.
FIG. 1A depicts a slotted cylinder according to an illustrative embodiment of the invention.
FIG. 1B depicts a key according to an illustrative embodiment of the invention.
FIG. 1C depicts a key tool according to an illustrative embodiment of the invention.
FIG. 2A depicts a sleeve according to an illustrative embodiment of the invention.
FIG. 2B depicts a cross-sectional view of a middle section of a sleeve according to an illustrative embodiment of the invention.
FIG. 3 depicts a slotted cylinder being engaged with a key in a sleeve according to an illustrative embodiment of the invention.
FIG. 4 depicts a slotted cylinder being engaged with a key in a sleeve in an aperture according to an illustrative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention provide a locking device that may be used in conjunction with NIDs and may be manufactured using relatively inexpensive materials.
FIGS. 1A-C depict an embodiment of the invention comprising a slotted cylinder 100 and a key 102 . FIG. 1A depicts a slotted cylinder 100 . The slotted cylinder 100 has a first end 104 , a second end 106 and a first slot 108 . The first slot 108 has a distal end 110 and a proximate end 112 . The slot's proximate end 112 coincides with the cylinder's first end 104 . The slot 108 extends from the first cylinder end 104 longitudinally and partially toward the second cylinder end 106 . The cylinder 100 has a second slot 114 extending from the first slot distal end 110 at an angle 140 to the first slot 108 . The second slot 114 may be straight or arced. The cylinder 100 may be provided with a resistance component 116 which is contained in the cylinder 100 at its second end 106 . Preferably the resistance component 116 is affixed to the inside of the slotted cylinder second end 106 .
FIG. 1B depicts the key 102 . The key 102 has a shaft 118 with a head 120 at a first end 122 of the shaft 118 , and a flange 124 extending from, and at an angle 142 to, a second end 126 of the shaft 118 . The key head 120 has a cavity 128 operably mateable with a key tool 130 . For example, the cavity may have a star or plus shape, into which a complementaly-shaped tool may be inserted. Additional examples of cavity shapes include triangle, square, “H”, pentagon, and “T”.
The key tool 130 may have any overall shape that enables a user to grasp and rotate it when engaged with the key. FIG. 1C depicts an illustrative embodiment of the key tool 130 with a key tool head 136 complementary in shape to the cavity 128 shown in FIG. 1 B. They key tool 130 has a handle 132 used to turn the tool. A screwdriver-type handle in line with the key tool shaft 134 is a further example of a functional design.
The key flange end is inserted into the first slot 108 of the cylinder at the cylinder's proximate end 112 until it contacts the resistance component 116 . The key 102 is then moved an additional amount toward the slot distal end 110 until it encounters and compresses the resistance component 116 . Once compressed the resistance component 116 provides a force on the key 102 in a direction longitudinally along the key shaft 118 toward the slot proximate end 112 .
The key tool 130 is then inserted into the key head cavity 128 . Using the key tool 130 , the key 102 is rotated around an axis defined by the length of the shaft 118 so that the key flange 124 moves into the second slot 114 , thereby locking the key 102 into the slotted cylinder 100 .
The resistance component 116 may be any structure that would provide sufficient pressure on the key 102 so that the key 102 is not free to slide out of the second slot 114 . The resistance component 116 may be, for example, a metal coil such as a spring, rubber stop, elastomeric polymer, pliable plastic or other elastic material.
A further embodiment of the invention is depicted in FIGS. 2A-B and FIG. 3 . This embodiment includes a cylindrical sleeve 200 which may provide additional security. FIG. 2A depicts an embodiment of the sleeve 200 . The sleeve 200 has a first end 202 and a second end 204 and is divided into at least three sections 206 , 208 and 210 . The first section 206 has an inner diameter L 1 which is larger than the outer diameter of the slotted cylinder 100 so that the slotted cylinder 100 may fit into the sleeve 200 . The first section 206 extends from the first sleeve end 202 to a length corresponding at least to the length of the slotted portion of the slotted cylinder 100 . The second sleeve section 208 may have a diameter L 2 which is larger than the key head 120 so that the key head 120 may fit in the sleeve 200 . Preferably the second section 208 extends from the second sleeve end 204 to a length sufficient to cover key 102 to the extent necessary to require the key tool 130 to disengage the key 102 from the slotted cylinder 100 . The key tool 130 will generally be necessary for disengagement if the key head 120 is not protruding enough from the sleeve 200 to grasp it firmly enough to turn the key 102 . The third sleeve section 210 is between the first and second sleeve sections 206 , 208 . The inner diameter L 3 of the third section is larger than the key shaft diameter and smaller than the key head diameter. The third section 210 need only be as long as is necessary for the section to have the structural integrity necessary to provide the desired security. Too thin a third section 210 may weaken the device and not satisfactorily protect against tampering. As depicted in FIG. 2B, the third section 210 may have a slot 212 extending along the length of the section and cut partially into the cylinder wall to accommodate the key flange 124 when the key is positioned into the cylinder 100 through the sleeve 200 . The slot 212 is only necessary if the length of the flange 124 is greater or equal to the radius of the key head 120 or if additional security is desired. The reason for this will become apparent when the operation of the sleeve is described below.
Operation of the sleeve 200 is depicted in FIG. 3 . The key 102 is placed, flange end first, into the sleeve 200 at the sleeve second end 204 . The slotted cylinder 100 is placed, first end 104 first, into the sleeve 200 at the sleeve first end 202 . They key flange 124 is aligned with the slot 212 (not shown) in the sleeve wall of the third section 210 , if such a slot exists, as it is put through the sleeve 200 . The key flange 124 is also aligned with the first slot 108 in the slotted cylinder 100 as the key 102 enters the slotted cylinder 100 . The key 102 is pushed into the sleeve 200 and the cylinder 100 until it meets the resistance component 116 . At that point the key 102 is pushed farther until the key flange 124 reaches the second slot 114 and can be rotated so that the flange 124 is engaged with the second slot 114 . This leaves the key 102 engaged with the slotted cylinder 100 with the sleeve 200 surrounding the engaged key and cylinder. In the embodiment depicted in FIG. 3, the diameter L 3 of the third sleeve section 210 is smaller than the key head 120 or the slotted cylinder collar 220 , or both so that the sleeve 200 cannot be slid over the engaged key and cylinder. The key 102 is locked into the slotted cylinder 100 and may have the sleeve 200 over the key head 120 so that the key 102 cannot be turned without the key tool 130 .
FIG. 4 depicts the key 102 and the slotted cylinder 100 being slid into the sleeve 200 . In a preferred embodiment, when the key 102 is engaged with the cylinder 100 , the uncollared end of the sleeve 200 abuts the collar 220 of the slotted cylinder 100 , and the outer face of the key head 102 is nearly flush with the outer face of the collar 218 .
As depicted in FIG. 4, the sleeve-covered lock 410 is particularly useful in conjunction with a latch. Latch may comprise two apertured parts, a tab 402 and a lid 404 , having apertures 418 and 416 , respectively. The apertured tab 402 fits through the lid aperture 416 so that the tab aperture 418 may accommodate the sleeve-covered lock 410 . When used with such a latch, the sleeve second end 204 and the slotted cylinder second end 106 may be fashioned with collars 218 and 220 , respectively, so that the sleeve-covered lock 410 cannot be pulled through the tab aperture 418 . A comparable configuration may be used on ND cover.
Although suitable for communication systems having NIDs, the locking device is also usable in other devices, such as lockers, utility boxes, tool boxes, protecting units, security systems and the like.
The sleeve 200 may have a collar 218 on at least one end. The sleeve collar 218 provides a barrier so that the sleeve-covered lock 410 cannot be slid through an aperture. As pictured in FIG. 3, the sleeve collar 218 is not necessary at the slotted cylinder end of the sleeve if a collar 220 exists on the slotted cylinder 100 . In the embodiment depicted in FIG. 3, the slotted cylinder 100 fits into the sleeve 200 only as far as the collar 220 . Therefore, when the sleeve 200 is over the engaged key 102 and slotted cylinder 100 , there is a collar at each end of the sleeve-covered lock to keep the device from sliding through the aperture 418 .
In a further illustrative embodiment, such as depicted in FIG. 2A, the sleeve 200 contains two collars 218 to keep the device from sliding through the aperture. In this embodiment, the slotted cylinder 100 can be placed entirely in the sleeve 200 , providing additional security. The inner diameter L 3 of sleeve section 210 will keep the engaged key and slotted cylinder from sliding out of the sleeve 200 .
The sleeve 200 may function without any collar if, in addition to the slotted cylinder 100 having a collar 220 , the key head 120 is larger than the sleeve second end 204 so that the sleeve 200 cannot slide over the key 102 when the key 102 is locked into the slotted cylinder 100 . The key head 120 would have to be larger than the aperture 418 through which the sleeve-covered lock is placed. Preferably the key head 120 is very thin so it could not be easily grasped and turned without a key tool 130 . A thicker key head 120 could be used in this fashion if for example, it was convex.
Advantageously, one or more parts of the locking device may comprise plastic or other economical material. The locking device, however, may be made of any material that can be formed into the desired parts and that exhibits the structural integrity necessary to provide the desired security. A further illustrative example of a locking device material is metal.
While the invention has been described by illustrative embodiments, additional advantages and modifications will occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to specific details shown and described herein. Modifications, for example, to the shapes of the key, key tool, slotted cylinder and sleeve, and to the materials used to fabricate the device, may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiments but be interpreted within the full spirit and scope of the appended claims and their equivalents. | A locking device suitable for NID housing security. The device includes a slotted cylinder, a key and key tool. The slotted cylinder has a resistance component contained in the cylinder. The key is mateable with the slotted cylinder and is held in place by the force of the resistance component. The key head has a cavity therein of a complimentary shape to the key tool so that the tool may be used to turn the key for locking or unlocking. A cylindrical sleeve is used for additional security. The sleeve fits over the mated key and slotted cylinder to protect against release of the parts and may further provide a barrier to removal from a structure being locked. By use of different key head cavity shapes each subscriber may only access their own line in a NID. | 8 |
BACKGROUND
Internet access is increasingly provided via high speed connections. High capacity data networks are currently offered over cable, fiber connections, and wireless networks. For example, cellular systems operate 3G (CDMA and UMTS/HSPA) and next generation 4G networks that utilize new and efficient protocols, such as Worldwide Interoperability for Microwave Access (WiMAX) and Long Term Evolution (LTE) among others to provide increasing bandwidth and coverage.
A networked device, such as a portable computer, a tablet, a smartphone, a laptop or a mobile device, may be entitled to connect to more than one network. The choice of the network may be determined by rules that are enforced by a connection manager. For example, when multiple networks are available, a rule might direct a networked device to select a network in a certain order, such as Wi-Fi, then 4G, then 3G. The connection manager may be embedded (or reside) within the networked device, or removably installed on the networked device to facilitate access by the networked device to the available networks that the networked device is entitled to use.
Network availability may be dynamic. A network may suddenly become unavailable because of a network outage, because the networked device moved out of range of the network or because the networked device moved in range of a more desirable network. When connected to a wireless network through a networked device, a user may want to keep track of his or her session usage and time. For example, a user may travel with a networked device that establishes temporary connections with multiple wireless networks. A wireless connection may initially be provided on a 3G network. This connection may be terminated because of the mobile user moving out range of the 3G network or because the mobile device has determined that a better signal is provided by another network, such as a 4G network. The transition between the 3G and the 4G network may be unnoticed by the user of the mobile device. From the perspective of the user, the Internet/data session is continuous. However, the networked device will log two distinct sessions. Typically, the clock that keeps track of the session time will also be reset as a consequence of the termination of the first session on a different network.
The user of the networked device will not, under these circumstances, have a record of the total session time that the networked device was connected nor of the data usage that matches the user's perception of the session time or the data usage.
SUMMARY
Embodiments are directed to a method for maintaining a measure of session time as a networked device establishes connections with different wireless networks.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram illustrating selected elements of a networked device including a sessions manager, which is part of a Connection Manager according to an embodiment.
FIG. 1B is a block diagram illustrating selected elements of a networked device connected to a network card that includes a sessions manager according to an embodiment.
FIG. 2 is a block diagram illustrating a sessions manager according to an embodiment.
FIG. 3 is a block diagram illustrating a sessions usage meter according to an embodiment.
FIG. 4 is a block diagram illustrating a sessions history according to an embodiment.
DETAILED DESCRIPTION
As used herein, “networked device” encompasses a device that either natively or by virtue of functionality of an add-on device may access multiple wireless networks. By way of illustration and not by way of limitation, a networked device may be a portable computing device such as a laptop computer or a tablet, or it may be a telecommunications device such as a smartphone that is capable of connecting to a wireless data network.
As used herein, an “available network” is a network to which a networked device is entitled to connect and that meets or exceeds minimum criteria for connectivity.
As used herein, a “connection manager” is a functional element that may be executed in hardware or software and that applies rules to determine which available network a networked device connects to when more than one network is available and that provides a sessions manager information relating to the status of a network connection.
FIG. 1A is a block diagram illustrating selected elements of a networked device including a sessions manager according to an embodiment. The networked device 102 comprises a CPU 104 , a memory 106 , a video RAM 112 , a video processor 114 , a bus 116 , a multiband wireless network adapter 122 and a connection manager 126 .
The various functions described below may be performed by CPU 104 in conjunction with instructions provided to it by other elements. Alternatively, a particular element may include a processor to perform the functions assigned to the particular element.
The networked device 102 may be a computing device in which case the networked device 102 would further comprise applications and hardware elements that provide computing functionality. For example, the networked device 102 may include applications and hardware elements for data storage, data entry, user input, web access, email, and word processing among other functions.
The networked device 102 may also serve to provide voice communications in which case the networked device 102 would further comprise applications and hardware to provide voice communications functionality. For example, the networked device 102 may include applications and hardware for data storage, data entry, user input, web access, email, telephone dialing and voicemail among other functions.
The networked device 102 further comprises a connection manager 126 that applies rules to select a wireless network from available wireless networks which the network device is authorized to use and to facilitate the connection of the networked device 102 to the selected wireless network. The connection manager 126 also manages the reconnection of lost connections and maintains a log of network connection status.
A sessions manager application 110 communicates with or receives communications from the connection manager 126 . The sessions manager application 110 is further illustrated in FIG. 2 .
Referring again to FIG. 1A , the multiband wireless network adapter 122 , the connection manager 126 and the session manager application 110 are illustrated as native elements of the networked device 102 . However, this is not meant as a limitation. In an embodiment illustrated in FIG. 1B , these elements may be incorporated into a network card 118 and connected to the bus 116 of the networked device 102 via an external interface 120 .
For example, network card 118 may connect to the networked device 102 via a USB port, a Peripheral Component Interconnect Express (PCI-E) port, or a mini-PCI-E port.
Referring to FIG. 2 , the sessions manager application 110 comprises a sessions monitoring module 204 . The sessions monitoring module 204 communicates with the connection manager 126 to monitor the status of the network connection. One task of the sessions manager application 110 is to monitor the time that the multi-band wireless network adapter 122 is connected to a particular network.
In an embodiment, the sessions monitoring module 204 receives (for example, via a message) or acquires (for example, via polling) an alert that a current network connection has been lost. The alert also provides an indication whether the connection was terminated at the direction of the user or lost for any other reason. A session that is not terminated by the user may sometimes be referred to herein as an “interrupted session.” The sessions monitoring module 204 provides this time data to a sessions log 202 . A sessions rule processor 206 receives or acquires the connection data from the sessions log 202 and processes the data according to rules established by the user, by the provider of the sessions manager, or by the provider of the networked device. In an embodiment, the sessions rule processor 206 produces a graphical display in the form of a sessions usage meter (see FIG. 3 ).
In an embodiment, the sessions rule processor 206 may apply a rule that measures an elapsed time between a session that was interrupted and the beginning of a next session. An elapsed time threshold may be established that determines whether the two sessions are to be displayed as a continuous session. For example, if the first session is terminated and the next session is automatically instigated within a time period of less than or equal to three minutes, the sessions rule processor 206 may treat the session as continuous and display a continuous session time. If however, the next session does not begin within the elapsed time threshold, the sessions rule processor 206 will treat the session as terminated. In this case, the next session will be treated as a new session having a session time that is independent of the session time of the terminated session.
The threshold referenced in the example provided above is exemplary and is suggested for illustrative purposes. Other thresholds may be established. In an embodiment a threshold may be established within a range of ten seconds to three minutes.
FIG. 3 is a block diagram illustrating a sessions usage meter according to an embodiment.
In an embodiment, a usage meter 302 is a graphical representation of the status of a current network connection. The graphical representation is displayed on the screen of a networked device and provides the user of the device information such as the network to which the device is connected 304 , other connections that are available 306 , the signal strength of the current connection 308 , and usage information 310 . The usage information 310 provides the user the session time based on rules as previously described. A tools icon 312 provides access to additional information regarding session times and session history.
FIG. 4 is a block diagram illustrating a sessions history according to an embodiment. The sessions history may be accessed via the usage meter as previously described. However, this is not meant as a limitation. The sessions history may be accessible via an application or directly via a shortcut or link.
The sessions history provides detailed information regarding the networks accessed over a selected period of time. As illustrated in FIG. 4 , the sessions history may be filtered using drop-down menus to allow the user to obtain a report of network usage based on the technology used or the type of entry.
The foregoing method descriptions and the process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the order of steps in the foregoing embodiments may be performed in any order. Further, words such as “thereafter,” “then,” “next,” etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods.
The various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
The hardware used to implement the various illustrative logics, logical blocks, modules, and circuits described in connection with the aspects disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but, in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Alternatively, some blocks or methods may be performed by circuitry that is specific to a given function.
In one or more exemplary aspects, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. The blocks of a method or algorithm disclosed herein may be embodied in a processor-executable software module, which may reside on a computer-readable medium. Computer-readable media include both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A storage media may be any available media that may be accessed by a computer. By way of example, and not limitation, such computer-readable media may comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, USB drives or any other medium that may be used to carry or store desired program code in the form of instructions or data structures and that may be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. Disk and disc, as used herein, include compact disc (CD), laser disc, USB drive, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. Additionally, the operations of a method or algorithm may reside as one or any combination or set of codes and/or instructions on a machine readable medium and/or computer-readable medium, which may be incorporated into a computer program product.
The preceding description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the following claims and the principles and novel features disclosed herein. | Systems and methods for maintaining a measure of session time of a networked device. A session between the networked device and a first network is monitored to determine a first session time. The first session time is indicative of a first time increment the networked device is continuously connected to the first network. A next session between the networked device and a second network is monitored to determine a second session time. The second session time is indicative of a second time increment the networked device is continuously connected to the second network. A time interval between termination of the session and commencement of the next session is determined. A rule is applied to determine whether the time interval is less than or equal to a pre-determined value. A session time equal to the sum of the first session time and the second session time is displayed when the time interval is less than or equal to the pre-determined value. A session time equal to the second session time is displayed when the time interval is greater than the pre-determined value. | 7 |
This application is a divisional of U.S. application Ser. No. 13/709,901, filed Dec. 10, 2012, which claims benefit of priority from the prior Japanese Application No. 2011-272091, filed Dec. 13, 2011; the entire contents of all of which are incorporated herein by reference.
TECHNICAL FIELD
This invention relates to a semiconductor device.
BACKGROUND
Recently, there are semiconductor devices having a package-on-package (PoP) structure in which a plurality of semiconductor packages are stacked one on another.
A technical literature relating to this is exemplified by Japanese Laid-Open Patent Publication No. 2009-70965 (Patent Document 1), which discloses such a semiconductor device having a PoP structure.
When controller and memory packages are stacked in this PoP structure, in general, the lower package is constituted by a controller chip, while the upper package is constituted by a memory chip. The upper package is connected to the lower package at the periphery of the lower package board, and hence external terminals (bump electrodes) are arranged only on the periphery of the upper package board.
However, in the upper package having the external terminals arranged only on the periphery, it is difficult to establish linear connection from a bonding pad to a land in an area where bonding pads of the wiring board are arranged closely to each other (dense wiring area).
Therefore, a wire is led from a bonding pad on one surface of the wiring board toward a central part thereof, then led to the other surface of the wiring board through a through via, and connected to a land arranged on the periphery of the other surface. As a result, the wiring length of the wiring on the wiring board is increased.
SUMMARY
In one embodiment, there is provided a semiconductor device comprising:
an insulating substrate including a first surface and a second surface opposite to the first surface;
a semiconductor chip including a plurality of first electrodes thereon, the semiconductor chip being mounted over the first surface of the insulating substrate, the first electrodes including signal electrodes, power-supply electrodes and ground electrodes;
a plurality of connection pads provided on the first surface of the insulating substrate, the connection pads including signal connection pads electrically connected to the signal electrodes, power-supply connection pads electrically connected to the power-supply electrodes and ground connection pads electrically connected to the ground electrodes;
a plurality of lands provided on the second surface of the insulating substrate, the lands including signal lands, power-supply lands and ground lands; and
a plurality of through vias penetrated from the first surface to the second surface of the insulating substrate, the through vias including signal vias electrically connected the signal connection pads to the signal lands, power-supply vias electrically connected the power-supply connection pads to the power-supply lands and ground vias electrically connected the ground connection pads to the ground lands, at least one of the signal vias being closer to the connection pads than immediately adjacent one of the power-supply vias or the ground vias.
In another embodiment, there is provided a semiconductor device comprising:
a wiring board including a first surface, a second surface opposite to the first surface, and wiring patterns, each of the wiring patterns comprises a connection pad formed on the first surface, a land formed on the second surface, a through via formed in the wiring board, a first wiring electrically connected the connection pad to the through via and a second wiring electrically connected the land to the through via; and
a semiconductor chip mounted over the first surface of the wiring board, the semiconductor chip including a plurality of electrodes thereon, the electrodes being electrically connected to the connection pads of the wiring patterns, and the electrodes including signal electrodes, power-supply electrodes and ground electrodes,
wherein the wiring patterns include signal wiring patterns electrically connected to the signal electrodes, power-supply wiring patterns electrically connected to the power-supply electrodes and ground wiring patterns electrically connected to the ground electrodes, and at least one of the signal wiring patterns is shorter than immediately adjacent one of the power-supply wiring patterns or the ground wiring patterns.
In the other embodiment, there is provided a semiconductor device comprising:
a wiring board defined by a first major surface, a second major surface facing the first major surface, and a plurality of side surfaces;
a semiconductor chip mounted on the first major surface, having a side surface facing one side surface of the plurality of side surfaces, and having a plurality of electrodes arranged along the faced side surface;
a plurality of connection pads provided on the first major surface of the wiring board between the one side surface of the wiring board and the faced side surface of the semiconductor chip and electrically connected to the plurality of electrodes of the semiconductor chip;
a plurality of external terminals provided on the second major surface of the wiring board, along and close to the one side surface of the wiring board;
a plurality of first through vias formed in the wiring board to penetrate from the first major surface to the second major surface in positions overlapping with the semiconductor chip;
a plurality of first wirings formed on the first major surface of the wiring board to electrically connect the first connection pads to the first through vias;
and a plurality of second wirings formed on the second major surface to electrically connect the external terminals to the first through vias,
wherein:
the electrodes include signal electrodes and power-supply and ground electrodes,
the first through vias include a plurality of signal through vias electrically connected to the signal electrodes, and a plurality of power-supply and ground through vias electrically connected to the power-supply and ground electrodes, and,
the signal through vias are arranged at positions closer to at least the one side surface than the power-supply and ground through vias adjacent to the respective signal through vias.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present invention will be more apparent from the following description of certain preferred embodiments taken in conjunction with the accompanying drawings, in which
FIG. 1 is a cross-sectional view showing a configuration of a semiconductor device having a PoP structure according to a first embodiment of the invention;
FIG. 2 is a plan view showing a schematic configuration of an upper package (memory package) that is the semiconductor device according to the first embodiment of the invention;
FIG. 3 is a cross-sectional view showing a schematic configuration of an upper package (memory package) that is the semiconductor device according to the first embodiment of the invention;
FIG. 4A is a plan view for explaining a reference example of a wiring pattern of a semiconductor device;
FIG. 4B is a plan view for explaining the reference example of the wiring pattern of the semiconductor device;
FIG. 5A is a plan view showing a schematic configuration of a wiring pattern of the semiconductor device according to the first embodiment of the invention;
FIG. 5B is a plan view showing a schematic configuration of the wiring pattern of the semiconductor device according to the first embodiment of the invention;
FIG. 6A is a cross-sectional view showing an assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 6B is a cross-sectional view showing the assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 6C is a cross-sectional view showing the assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 6D is a cross-sectional view showing the assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 6E is a cross-sectional view showing the assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 6F is a cross-sectional view showing the assembly flow of the semiconductor device according to the first embodiment of the invention;
FIG. 7 is a plan view showing a schematic configuration of a semiconductor device according to a second embodiment of the invention;
FIG. 8 is a cross-sectional view showing the schematic configuration of the semiconductor device according to the second embodiment of the invention;
FIG. 9A is a plan view showing a schematic configuration of a wiring pattern of the semiconductor device according to the second embodiment of the invention;
FIG. 9B is a plan view showing the schematic configuration of the wiring pattern of the semiconductor device according to the second embodiment of the invention;
FIG. 10 is a plan view showing a configuration of a semiconductor device according to a third embodiment of the invention;
FIG. 11A is a plan view showing a configuration of a wiring pattern of the semiconductor device shown in FIG. 10 ;
FIG. 11B is a plan view showing the configuration of the wiring pattern of the semiconductor device shown in FIG. 10 ;
FIG. 11C is a plan view showing the configuration of the wiring pattern of the semiconductor device shown in FIG. 10 ;
FIG. 12 is a plan view showing a configuration and a wiring pattern of the semiconductor device according to the third embodiment of the invention;
FIG. 13A is a plan view showing a configuration of a semiconductor device according to a fourth embodiment of the invention;
FIG. 13B is a plan view showing the configuration of the semiconductor device according to a fourth embodiment of the invention; and
FIG. 14 is a cross-sectional view showing a configuration of a semiconductor device according to a fifth embodiment of the invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present invention will be now described herein with reference to illustrative exemplary embodiments. Those skilled in the art will recognize that many alternative embodiments can be accomplished using the teachings of the present invention and that the invention is not limited to the exemplary embodiments illustrated for explanatory purposes.
Exemplary embodiments of the invention will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional view showing a configuration of a semiconductor device having a package-on-package (PoP) structure.
A semiconductor device 1000 of a PoP structure has an upper package (memory package) 100 and a lower package (controller package) 200 .
In the lower package 200 , a controller chip 202 is flip-chip mounted on a wiring board 201 , and lands 203 are arranged around the controller chip 202 on one surface of the wiring board 201 so that the lower package 200 is connected to the upper package 100 through these lands 203 . Solder balls 204 are provided on the other surface of the wiring board 201 . The upper package 100 is stacked and mounted on the upper side of the lower package 200 .
In the upper package 100 , solder balls 102 serving as external terminals are arranged in two rows along the periphery of the other surface of the wiring board 101 such that they will not come into contact with the controller chip 202 of the lower package 200 .
Referring to FIGS. 2 and 3 , a configuration of the upper package (memory package) 100 will be described in detail. FIG. 2 is a plan view showing a configuration of the upper package 100 , while FIG. 3 is an A-A′ cross-sectional view showing the configuration of the upper package 100 . Hereinafter, the upper package 100 shall be referred to as the semiconductor device.
As shown in FIGS. 2 and 3 , a first semiconductor chip (first memory chip) 103 is mounted in a substantially central part on one surface of the wiring board 101 with its circuit formation surface facing upward, by means of an adhesive member 113 . The wiring board 101 may be a glass-epoxy wiring board, for example.
The first semiconductor chip 103 has a substantially rectangular plate shape, for example, and has a plurality of electrode pads 104 arranged on each of its short sides. In the first semiconductor chip 103 , more electrode pads 104 are arranged on one of the short sides than on the other short side (see FIG. 2 ).
A second semiconductor chip (second memory chip) 105 is mounted on top of the first semiconductor chip 103 with its circuit formation surface facing upward. The second semiconductor chip 105 is configured in the same manner as the first semiconductor chip 103 . Specifically, the second semiconductor chip 105 has, for example, a substantially rectangular shape, and has a plurality of electrode pads 106 arranged on each of its short sides (see FIG. 2 ). In the second semiconductor chip 105 , more electrode pads 106 are arranged on one of the short sides than on the other short side. The second semiconductor chip 105 is stacked in a position rotated by 90 degrees with respect to the first semiconductor chip 103 such that the electrode pads 104 of the first semiconductor chip 103 are exposed.
A plurality of connection pads 107 are arranged on one surface of the wiring board 101 in correspondence with the electrode pads 104 of the first semiconductor chip 103 and the electrode pads 106 of the second semiconductor chip 105 . The electrode pads 104 of the first semiconductor chip 103 and the electrode pads 106 of the second semiconductor chip 105 are connected to the corresponding connection pads 107 by means of electrically conductive wires 108 made of Au or the like.
A sealer (sealing resin) 109 is formed on one surface of the wiring board 101 so as to cover the first semiconductor chip 103 , the second semiconductor chip 105 and the wires 108 .
A plurality of lands 110 are arranged on the other surface of the wiring board 101 , and each of the lands 110 is provided with a solder ball 102 . The lands 110 and the connection pads 107 are connected to each other by wirings 112 via through vias 111 formed in the wiring board 101 .
Referring to FIGS. 4A and 4B , a reference example of a wiring pattern of a semiconductor device will be described.
In a PoP Structure, in general, the wiring length can be made shorter in comparison with a system in which a controller and a memory are arranged side by side on a system board. Therefore, good waveform quality can be ensured without the need of termination. However, the demand for increased operating speed knows no bounds, and today even a package of a PoP structure is required to be designed to further reduce the wiring length.
When designing a package for an operating speed from 400 Mbps to 800-1066 Mbps, as shown in FIGS. 4A and 4B , measures may be taken against noise in a package board by arranging a large number of through vias for a shield line that is used to reduce crosstalk noise between signals and to reduce loop inductance from signal to power supply/GND.
In order to realize the operating speed of 1600 Mbps, improvement in other factors than the package design is necessary, such as improvement of a driver or receiver, reduction of terminal capacity, and the like. However, the package design for realizing reduction of wiring length remains a major problem in realizing the operating speed of 1600 Mbps.
In addition to routing of the shield line, various factors interfere with reduction of wiring length. These factors include, for example, arrangement of power supply and GNB, and signals allocated to the package, restrictions to via diameter and via arrangement in production of a package board, and trade-off between reduction of the package size and increase of the semiconductor device's die size for meeting the demand for increased capacity.
As shown in FIGS. 4A and 4B , when a signal wiring 401 is routed in a region of the wiring board 400 where the wiring density is high, the signal wiring 401 is routed from a connection pad 402 toward inside of the wiring board 400 and then turned back toward corresponding one of lands 404 to 406 through a signal through via 403 and connected to this land. In order to reduce the wiring length of the signal wiring 401 routed in this manner, the signal through via 403 must be located as close as possible to the corresponding one of the lands 404 to 406 .
However, if many through vias are provided for power-supply and ground wirings 407 and 408 , power-supply and ground wirings 407 and 408 will be routed in a wiring width close to the via diameter. In addition, it becomes difficult to ensure an area for arranging through vias 403 for signal wirings at positions close to the lands 404 to 406 due to the presence of the through vias for the power-supply and ground wirings 407 a and 408 , and thus the signal wirings 401 have to be routed to an area where the through vias 403 for the signal wirings can be arranged. As a result the wiring lengths of the signal wirings are increased.
Referring to FIGS. 5A and 5B , a wiring pattern of a semiconductor device 100 according to an exemplary first embodiment of the invention will be described. FIGS. 5A and 5B are plan views showing a schematic configuration of a wiring pattern of the semiconductor device 100 according to the first embodiment.
In order to solve the problems arising in the reference example of the wiring pattern shown in FIGS. 4A and 4B (e.g. increased wiring length of the signal wirings), through vias for a signal wirings are arranged at a position close to corresponding lands, while through vias for power-supply and ground wirings are not arranged closer to the lands than the signal wirings except for those effective to reduce the inductance, so that the widths of the power-supply and ground wirings are not increased. This makes it possible to ensure an area where through vias for signal wirings can be arranged in a region with a high wiring density, and to reduce the wiring lengths of the signal wirings.
Referring to FIGS. 5A and 5B , a wiring pattern of the semiconductor device 100 according to the first embodiment of the invention will be described in detail.
In a wiring board 500 (corresponding to the wiring board 101 of FIG. 2 ) used in the semiconductor device 100 according to the first embodiment, the density of wiring patterns is high, for example, in a region on the end side where a large number of electrode pads 104 are arranged in the first semiconductor chip 103 that is a memory chip (see FIG. 2 ).
In this region with a high density of wiring patterns, as shown in FIGS. 5A and 5B , for example, the inductance depends on a distance from the lands 501 to 503 to the connection pads 504 . Therefore, the power-supply and ground wirings are such that only the through vias 505 and 506 located close to the connection pad 504 are left while they are arranged at positions further away from the connection pads 504 than the signal through vias 507 .
Further, in a region with a high density of wiring patterns, the power-supply and ground wirings are not formed in a solid pattern but formed to have the same width as that of the signal wirings 508 (while the power-supply and ground wirings are formed in a solid pattern in a region with a high density of wiring patterns in FIGS. 4A and 4B , they are not formed in a solid pattern in FIGS. 5A and 5B ).
This configuration makes it possible to reduce the inductance of the power-supply and ground wirings, and to arrange the signal through vias 507 at positions close to the connection pads 504 in a region with a high wiring density. Since the signal through vias 507 can be arranged at positions close to the connection pads 504 , the wiring lengths of the signal wirings can be reduced in the semiconductor device of a PoP structure. Further, the reduction of the wiring lengths of the signal wirings ensures stable operation at a speed of 1600 Mbps or more, for example at 2133 Mbps
Referring to FIGS. 6A to 6F , an assembly flow of the semiconductor device 100 according to the exemplary first embodiment will be described. FIGS. 6A to 6F are cross-sectional views showing an assembly flow of the semiconductor device 100 according to the first embodiment. Like components or parts as those of FIG. 3 are denoted by the same reference numerals.
Firstly, a wiring board 101 as shown in FIG. 6A is prepared. Connection pads 107 are arranged on one surface of the wiring board 101 , and lands 110 are arranged on the other surface of the wiring board 101 .
Next, as shown in FIG. 6B , a first semiconductor chip 103 having an adhesive member 113 formed on the rear surface is mounted on the wiring board 101 . Further, a second semiconductor chip 105 having an adhesive member formed on the rear surface is stacked on the first semiconductor chip 103 .
Then, as shown in FIG. 6C , the electrode pads 104 of the first semiconductor chip 103 and the connection pads 107 of the wiring board 101 are electrically connected with wires 108 .
Each of the wires 108 is formed of Au or the like, and the tip of the wire 108 is molten to form a ball, which is ultrasonic thermocompression-bonded onto the electrode pad 104 of the first semiconductor chip 103 by means of a wire bonding device (not shown). The wire 108 is then formed into a predetermined loop shape and the tail end of the wire 108 is ultrasonic thermocompression-bonded to the corresponding connection pad 107 , whereby the wire connection is completed.
As show in FIG. 6D , a sealing resin (sealer) 109 is formed on one surface of the wiring board 101 by collective molding. The sealing resin 109 is formed, for example, by clamping the wiring board 101 with a molding unit composed of upper and lower molds of a transfer mold device (not shown), forcing a thermosetting epoxy resin from a gate into a cavity formed by the upper and lower molds, and thermosetting the epoxy resin in the cavity.
After that, as shown in FIG. 6E , an electrical conductive solder ball 102 is mounted on each of lands 110 on the other surface of the wiring board 101 to form an external terminal (bump electrode). In this ball mounting process, a suction mechanism (not shown) having a plurality of suction holes formed in accordance with the arrangement of the lands 110 on the wiring board 101 is used to hold the solder balls 102 in the suction holes and to transfer flux to the solder ball 102 thus held, whereby the solder balls 102 are collectively mounted on the lands 110 of the wiring board 101 . The solder balls thus mounted are reflown to form external terminals.
The wiring board 101 on which the external terminal have been formed is cut and separated into pieces along dicing lines 600 , as shown in FIG. 6F . The board dicing is performed by attaching the sealing resin 109 of the wiring board 101 to dicing tape (not shown) so that the wiring board 101 is supported by the dicing tape. The wiring board 101 is cut along the longitudinal and transverse dicing lines 600 with a dicing blade (not shown), so that the wiring board 101 is separated into pieces. After completing the separation, each of the separated pieces is picked up from the dicing tape to obtain the semiconductor device 100 as shown in FIG. 3 .
Referring to FIGS. 7 and 8 and FIGS. 9A and 9B , a configuration of a semiconductor device according to an exemplary second embodiment of the invention will be described. FIG. 7 is a plan view and FIG. 8 is a cross-sectional view both showing a configuration of the semiconductor device according to the second embodiment. FIGS. 9A and 9B are plan views showing a wiring pattern of the semiconductor device according to the second embodiment.
While a semiconductor device 700 according to the second embodiment is configured in the same manner as the semiconductor device 100 according to the first embodiment, the semiconductor device 700 differs from the semiconductor device 100 according to the first embodiment in the arrangement of the first semiconductor chip 103 and the second semiconductor chip 105 . It should be noted that the same components and parts as those shown in FIGS. 2 and 3 are denoted by the same reference numerals.
In the second embodiment, as shown in FIGS. 7 and 8 , the first semiconductor chip 103 and the second semiconductor chip 105 are mounted on the wiring board 101 to be shifted toward the short sides thereof where a smaller number of electrodes pads 104 are arranged so as to ensure wider space on the short sides thereof where a greater number of electrode pads 104 are arranged.
The second embodiment provides the same advantageous effects as those of the first embodiment. In addition, according to second embodiment, the first semiconductor chip 103 and the second semiconductor chip 105 are shifted to the short sides where a smaller number of electrode pads 104 are arranged, whereby it is made possible to arrange signal through vias 111 between connection pads 107 and lands 110 . Further, the wiring lengths of the signal wirings can be reduced.
Furthermore, as shown in FIGS. 9A and 9B , through vias 505 effective for reducing the inductance of the power-supply and ground can be arranged between the connection pads 504 and an end of the wiring board 500 , which ensures a wider wiring area.
Next, referring to FIG. 10 , FIGS. 11A, 11B and 11C , and FIG. 12 , a configuration of a semiconductor device according to an exemplary third embodiment of the invention will be described. FIG. 10 is a plan view showing a schematic configuration of a semiconductor device according to the third embodiment. FIGS. 11A, 11B and 11C are plan views showing a schematic configuration of a wiring pattern of the semiconductor device shown in FIG. 10 . FIG. 12 is a plan view showing a schematic configuration of a wiring pattern of the semiconductor device according to the third embodiment.
One of reasons why wiring lengths of some of the signal wirings are increased resides in arrangement of solder balls allocated thereto.
As shown in FIG. 10 , for example, a signal relating to DQ_A may not be able to be allocated in one side (side 1) and may be allocated to extend to a different side (side 2). In this case, as shown in FIGS. 11A, 11B and 11C , a group of wirings with short wiring length (Gr) and a group of wirings with long wiring length (Gr) are produced, which poses a restriction to reduction of the wiring lengths of the signal wirings even if the configuration of the second embodiment is used.
According to the third embodiment as shown in FIG. 12 , therefore, solder balls 120 are arranged at a reduced pitch, or the number of rows of the solder balls 120 arranged along each side is increased, so that the total number of solder balls arranged along each side is increased. This makes it possible to allocate all the signal groups in one side, and to reduce the wiring lengths of the signal wirings.
Next, referring to FIGS. 13A and 13B , a configuration of a semiconductor device according to an exemplary fourth embodiment of the invention will be described. FIG. 13A is a schematic diagram showing a comparative example, and FIG. 13B is a plan view showing a schematic configuration of a semiconductor device according to the fourth embodiment.
As shown in FIG. 13B , the aspect ratio of the shape of the semiconductor chip 130 is set to a value close to one, and connection pads 131 are positioned away from solder balls 132 . This configuration makes it possible to ensure a sufficient wiring area and to route wirings from the connection pads 131 to the solder balls 132 without turning back.
Next, referring to FIG. 14 , a schematic configuration of a semiconductor device according to a fifth embodiment of the invention will be described.
Due to various restrictions caused by increased die size (chip size), reduced package size, and the like, connection pads are required to be positioned close to the periphery of the package.
In this case, as shown in FIG. 14 , a semiconductor chip (die) 142 is flip-chip mounted on a sub-printed board 141 placed on a package 140 , by means of bumps 143 and an electrode pads 144 , while bonding wires 145 are arranged on the inner side of the sub-printed board 141 , so that connection pads 146 are positioned on the inner side.
This makes it possible to route the wirings from the connection pads 145 to solder balls 147 without turning back.
Although the invention made by this inventor has been described with reference to the exemplary embodiments, the invention is not limited to the foregoing embodiments but may be modified in various manners without departing from the scope of the invention.
Although in the foregoing embodiments, the description has been made of a case where the invention is applied to a MCP (Multi Chip Package) in which two semiconductor chips are mounted in stack, the invention is also applicable to a BGA (Ball Grid Array) or a LGA (Land Grid Array) in which a single semiconductor chip is mounted. Further, the invention is also applicable to a MCP having three or more chips.
Further, although in the foregoing embodiments, the description has been made of a case where a glass-epoxy wiring board is used, the invention is also applicable to a flexible wiring board made of polyimide or the like, as long as the wiring board has external terminals arranged only on the periphery and has a region where wiring patterns are arranged densely. | A semiconductor device includes an insulating substrate including a first surface and an opposing second surface, and a semiconductor chip. The semiconductor chip is mounted over the first surface, includes signal electrodes, power-supply electrodes and ground electrodes, which connect to pads on the first surface of the insulating substrate. Lands provided on the second surface of the insulating substrate include signal lands, power-supply lands and ground lands through vias penetrate from the first surface to the second surface of the insulating substrate, and include signal vias electrically connected the signal connection pads to the signal lands, power-supply vias electrically connected the power-supply connection pads to the power-supply lands and ground vias electrically connected the ground connection pads to the ground lands. At least one of the signal vias are closer to the connection pads than immediately adjacent one of the power-supply vias or the ground vias. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
BACKGROUND OF THE INVENTION
[0003] Dot matrix printer assemblies utilize ribbon cartridges that contain continuous strip of material impregnated with an ink solution. The ribbon is contained in a cartridge container that normally mounts around the dot matrix printer's print head. As the ribbon passes between the printer head and a sheet of paper, information is then printer on to the sheet of paper.
[0004] In order to print the information, small rods or pins in the printer head are thrust into the ribbon, which then makes contact with the paper adjacent to the pins, thereby transferring ink from the ribbon to the paper. Through the proper combination of dots, the ink transferred is transformed into recognizable letters or symbols. The higher the impact force of the pins on the ribbon the darker the resulting image. Contemporary printers commonly produce a consistent impact force.
[0005] As the printer assembly moves across the sheet of paper, the ribbon formed as a continuous band, is also pulled laterally across the gap between the paper and the print head, continuously providing a new area to be struck by the pins in order to provide ink for the printing operation. If the ribbon did not continuously move, it would quickly wear out in response to repetitive striking of the same area.
[0006] At present, many pictures such as dot matrix printers, do not track ink usage. The user typically notices print cartridge deficiency only when the printer starts printing characters that are difficult to read. As a matter of practicality, it will often be the case that a replacement is not readily available. For a business, this often means extra cost incurred in the form of expedited shipping charges.
[0007] A second factor in obtaining optimum print quality and usage efficiency from an ink ribbon cartridge is the variations in print quality attributable to differences in the manufacture and type of ribbon. Competitive pressures cause some suppliers to use lower quality ribbon or inks, which may produce lighter images. In such cases the user may assume the problem is with the printer and not the ribbon.
[0008] Previous methods for determining the type of cartridges have included physical extrusions or indentations on the cartridge so that the printing unit can determine which cartridge model is being utilized. This has a limitation in that all of the possible permutations much be considered at the start of the program, in order to modify the tooling for the cartridge body and the sensors in the printing unit.
[0009] By contrast to prior art dot matrix printers, prior art laser printers have employed advanced systems for identifying cartridge mode. One such system is disclosed by U.S. Pat. No. 5,289,242 entitled “METHOD AND SYSTEM FOR IDENTIFYING THE TYPE OF TONER PRINT CARTRIDGES LOADED INTO ELECTROPHOTOGRAPHIC PRINTERS” issued to Christensen, et al. A metal label is installed on the print cartridge, and contacts in the laser printer are used to detect and connect the metal label to a DC voltage signal line. If there is no conductive metal strip, then the detected voltage level is at logic 1, or 5 volts. If there is a conductive metal strip, then detected voltage is at logic 0, or 0 volts. By passing current through the label and determining the results, the printer ascertains what type of cartridge is installed.
[0010] This system has the disadvantage that may not distinguish many types of cartridges. Moreover, if the label is dirty or improperly positioned, failure to detect cartridge type will result in assumption by the printer that no cartridge is installed, and thus the printer will not work. Furthermore, this system is inappropriate for dot matrix printers. The primary advantage of dot matrix printers over, for instance, laser printers is that both the printer and the ink cartridges are relatively inexpensive. The metal label component could be prohibitively expensive if applied to a dot matrix print cartridge.
[0011] A method and apparatus are provided for adaptively controlling printer functions of a dot matrix printer in response to sensing the type of printer ink cartridge being used. An identifying resistive valve is applied to surface of the cartridge and installed within the printer. The printer includes contacts that include sensors and sensor circuitry useful to detect a presence of the resistive indicator, and the resistive valve thereof. The sensed resistive valve is used to directly control printer functions, and/or to access stored data or printer control routines specific to the type of cartridge, or desired performance characteristics. Stored information, which may be appended by other sensed information such as printer usage data, is used to selectively regulate printer operation to achieve maximum efficiency and performance from the particular ink cartridge.
[0012] The resistive indicator may be applied directly to a surface of the cartridge, or to a label that may be adhesively applied to the cartridge, to facilitate compatibility with different cartridges. In some cases a cartridge may support different labels, each conforming a to a different operational status of the printer.
[0013] By means of the present invention, information respecting one or more characteristics of the ink cartridges can be adaptively factored into printer operation in order to enhance image quality and to enhance the operational life of the ink cartridge.
[0014] A display will and/or alarm may be incorporated into the invention to provide a visual indication of the printer/ink cartridge status, remaining life or ink cartridge, and other data.
[0015] The resistive ink identifier may be formed in different ways, to provide different resistive valves corresponding to operational parameters. In one embodiment the resistive ind identifier has a resistance valve that is a function of its length. In other embodiments the resistive valve of the ink identifier is a function of its width, or ink characteristics.
[0016] In the presently preferred embodiment print head impact force may be regulated, in response to sensed resistive valves by varying the pulse width of the print head activation coil. As would be apparent to those with ordinary skill in the yard, various other methods may be used to regulate functions such as printer impact force, without departing from the broader aspects of the invention, as set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:
[0018] [0018]FIG. 1 is a view of a print cartridge designed in accordance with the present invention;
[0019] [0019]FIG. 2 a is a view of a label with a resistive ink identifier;
[0020] [0020]FIG. 2 b is a view of a label with an alternate resistive ink identifier;
[0021] [0021]FIG. 3 is a view of a print cartridge designed in accordance with the present invention.
[0022] [0022]FIG. 4 a is a diagram of a basic implementation of sensor/regulation circuitry in a printer designed in accordance with the present invention.
[0023] [0023]FIG. 4 b is a diagram of a more advanced implementation of sensor/regulation circuitry in a printer designed in accordance with present invention;
[0024] [0024]FIG. 5 is a view of a striker of a dot matrix printer;
[0025] [0025]FIG. 6 is a graph showing how the strike force of the striker can be modified by changing pulse width;
[0026] [0026]FIG. 7 is a block diagram illustrating the method of using the sensor/regulation circuitry of FIG. 4 a;
[0027] [0027]FIG. 8 is a block diagram illustrating a basic method of using the sensor/regulation circuitry of FIG. 4 b.
[0028] [0028]FIG. 9 is a block diagram of an advanced method of using the sensor/regulation circuitry of FIG. 4 b.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In accordance with the present invention there is provided a device and method for sensing the presence and type of cartridge installed in a dot matrix printer and for modifying printer functionality in response to the sensed information.
[0030] In order to distinguish between different ink ribbon cartridge models, it is cost efficient to use only one sensor or one sensor set, and still permit the usage of many different ribbon ink cartridge models. An electronic component, mounted upon the cartridge exterior services to identify and distinguish the cartridge model but manufacturing cartridges including such a component would be expensive. Besides the cost of the component itself, contact areas would also have to be installed. However, if the component were in the presently preferred embodiment, the electronic component or idicia is implemented as a resistor, silk-screened directly on the cartridge exterior or onto a printed resistor label the resistance valve is used to signify, for example, the cartridge model and ribbon characteristics, such as ribbon type, length, ink density, etc. Where no resistor is sensed, for instance because an unclassified cartridge was installed, the cartridge would still function using default valves not optimized valves for printing. The silk-screened resistor could be silk-screened directly onto the cartridge at any convenient location. It could also be silk-screened onto a label that would be placed on the cartridge prior to shipment. The ability to add the resistor at any time would permit any cartridge presently in use to be classified and employed in connection with the present invention.
[0031] In the presently preferred embodiment of the present invention, the printer sensor is implemented by a simple pair of contacts which, when touching the silk-screened resistor, can be used to determine the resistance valve of the resistor. The valve of the silk-screened resistor is compared to a valve stored in memory of the printing unit. The stored valves are defined for known models and can also define extrapolated future models. The resistance valve could be used to regulate printer striking force, specify the number of characters that can be printed from the ribbon (length/type of ribbon), the amount of ink density or remaining ink on the ribbon, etc. Different resistive valves may be applied by varying the material used to fabricate the resistor, i.e. the use of different conductivity/resistivity materials. Alternatively, resistor paths lengths can be varied to produce different resistances while using the same conductivity materials. In another implementation different resistor valves are obtained by varying the length to width ratio of the resistor materials, as such, one of ordinary skill will recognize that technique for applying resistive indicators of various resistor valves, may vary, dependant upon cost, case of application, etc. A color-coding scheme would also be provided, so that the customer could more easily distinguished between and select different capacities for the tape ribbon cartridge by the resistor color.
[0032] Printer control circuitry can be used and optimized to vary the applied printing force for improved quality of readability. Printing force can be varied in response to contact factors, such as ribbon type, ribbon length and ink density. Printing force can also be varied in response to additional sensed parameters, such as ongoing ribbon usage (ribbon advance).
[0033] Printer control circuitry can also implement stored programs to selectively implement other functions, as most efficient for the sensed cartridge. For example, by knowing the type and capacity of the ribbon, and number of characters already punched, the remaining capacity of the particular cartridge can be known. As the ribbon is reaching the end of its ink supply, the time between pin strikes could also be lengthened to make the printed characters remain dark for longer, thereby increasing the life of the ink ribbon cartridge.
[0034] A LCD display can be used to display the remaining life of the ink ribbon cartridge and provide a visual and/or audio indication when the ink life is below a certain level. The level can be either stored or generated as the cartridge ink is being used, thereby providing an advance warning to the operator. As the ribbon cartridge is changed, the counter can be automatically zeroed.
[0035] Referring now to the drawings, FIG. 1 is a view of an exemplary ink cartridge designed in accordance with the present invention. Housing 1 contains the unexposed portion of the ribbon 3 as well as mechanisms (not shown) for cycling the ribbon through the exposure area 5 . A label 7 if affixed to the housing 1 . The label includes a resistive ink identifier 9 . Alternatively, the resistive ink identifier 9 could be affixed directly to the housing 1 . In a preferred embodiment of the invention, the resistive ink identifier is a silk screened conductive ink. The silk-screened conductive ink has the advantage of being cheap and easy to apply.
[0036] [0036]FIGS. 2 a and 2 b illustrate how the resistive valve of the resistive ink identifier can be varied by altering the length of the resistive ink identifier. In FIG. 2 a , the resistive ink identifier 11 follows the shortest possible path between the two contact points 13 and 15 . This resistive ink identifier 11 will therefore have a relatively low resistive valve. In FIG. 2 b , the resistive ink identifier 17 follows a relatively longer path between the two contact points 19 and 21 . This resistive ink identifier 17 will therefore have a higher resistive valve than the resistive ink identifier 11 of FIG. 2 a.
[0037] Resistance may be measured in ohms/square, and resistances range from less than one ohm/square to thousands of ohms/square. The resistance of an inked path is the product of the squares and the ohms/square. For example, a path of length L may be a total resistance of 1000 ohms. If the path were made twice as long or ½ as wide, the resistance would be 2000 ohms. The resistance would also become 2000 ohms if the ohms/square of the resistive material was doubled. By assigning ink cartridge characteristics to different resistive valves, the resistive valve of the resistive identifier can be used to represent those characteristics. For instance, the resistive valve of the restive ink identifier may be used to access information representative of various physical characteristics of the ink ribbon in the ink cartridge such as the length of the ribbon, the ink density of ink, the ribbon or optimum impact force. Alternatively, a ratio could be assigned between resistive valve and total ink capacity. In the latter case, the resistive valve would correspond directly to the ink capacity of the ink cartridge, The ink capacity could be measured by various means, but would probably be measured by an estimated number of characters that can be printed. As an additional feature, the resistive ink components may be color coded for convenient identification by a human user.
[0038] [0038]FIG. 3 illustrates an exemplary ink cartridge 23 ; designed in accordance with the present invention, installed into a dot matrix printer. In this view, it can be seen how the printer head 25 is interposed between the exposed area 27 of the ink ribbon 29 and the document 31 to be printed on, when the ink cartridge 23 is properly installed into the cartridge holder 33 . In order to print, pins on the printer head 25 are thrust toward the document 31 . Because the ink ribbon 29 is interposed between the printer head 25 and the document 31 , ink from the ink ribbon 29 is transferred to the document 31 as the pins urge the ribbon against the document. As the printer prints, the ink ribbon 29 is advanced across the exposed area 27 by a mechanism (not shown) in the print cartridge 33 .
[0039] When the ink cartridge 23 is installed into the cartridge holder 33 , contact points on the resistive ink identifier 39 are in electrical communication with contact 35 and 37 disposed on the cartridge holder 33 . The contracts 35 and 37 are in electrical communication with sensor/regulation circuitry 41 . The circuitry 41 is in electrical communication with print head activation circuitry 42 , which regulates movement of the printer head 25 or other functional components of the printer.
[0040] [0040]FIG. 4 a illustrates a basic hardware embodiment of the sensor/regulation circuitry 41 of FIG. 3. As shown, therein, a sensor 43 is operative to sense the resistive valve of the resistive ink identifier. Printer controller 45 is in electrical communication with the sensor 43 and is operative to regulate printing functions, e.g. impact force, in response to the sensed resistive valve. The printer controller 45 may comprise a simple comparator circuit (not shown) used to translate the sensed resistive valve into printer control data, if necessary.
[0041] [0041]FIG. 4 b illustrates a software embodiment utilizing memory 47 in electrical communication with the sensor 43 and printer controller 45 . In this embodiment, the memory is operative to store printer control data correlated to the identified type of cartridge, such as information on the length of the ink ribbon in the ink cartridge, and/or information on the density of ink on that ink ribbon. The memory can also store operational routines for directing printer functions in response to the specific data attributable to the identified cartridge.
[0042] When the sensor 43 senses the resistive valve of the resistive ink identifier, the memory responds to the sensed resistive valve by correlating the sensed resistive valve with printer control data in memory. The printer control data thus correlated and/or the corresponding operational routines are sent to the printer controller 45 , which regulates printing in response to that input.
[0043] [0043]FIG. 4 illustrates the mechanical method by which printing may be regulated in accordance with a preferred embodiment of the present invention. As striker 49 is operative to cause pins in the printer head to strike the document to be printed on (see FIG. 3) The striker may be connected to the pins of the printer head (see FIG. 3) in a variety of fashions as known in the art. The striker comprises a coil 51 disposed about a pin or ram 53 . Energizing the coil 51 causes the ram 53 to travel in a direction 55 to a strike point 57 . The strike point 57 is the point at which the pin in the printer head strikes the document to be printed (see FIG. 3).
[0044] Referring now to FIG. 6, it can be seen how the process of regulating impact force may be accomplished by means of a series of energizations of the coil, or pulses 59 a,b,c . Each pulse 59 a,b,c has a default pulse width 65 a,b,c , which represent the mount of time for which the coil is energized. Points 67 a,b,c which represents the amount of time for which the coil is energized. Points 67 a,b,c which represents the amount of time for which the coil is energized. Points 67 a,b,c represent points in time at which the ram reaches the strike point (see FIG. 50. kit can be seen from the drawing that the pulse width 65 a,b,c do not extend forth entire time between the points in time 67 a,b,c . In other words, the ram is not normally accelerated during the entire length of its travel to the strike point (see FIG. 5) Modification of the impact force of the print head, may therefore be, be accomplished by changing the pulse widths 65 a,b,c , of the pulses 59 a,b,c . For instance, a pulse width addition 69 a,b,c may be added to each pulse width 65 a,c,b . For instance, a pulse width addition 69 a,b,c , may be added to each pulse width 65 a,b,c . Referring again to FIG. 5, in so doing will resulting in the ram 53 being accelerated for a greater portion of the time spent traveling in the direction 55 to the strike point 57 . The ram 53 will thereby achieve a higher force by the time it reaches the strike point 57 , and the connected pion of the printer head will therefore strike the document to be printed on with more force (see FIG. 3). Accordingly, a relatively higher amount of ink will be transferred from the ink ribbon to the document to be printed on.
[0045] Correspondingly, reducing the pulse width will reduce the impact force, and lighten the resulting image. As those skilled in the art will recognize, the broader teachings of the present invention may be utilized not only to identify and implement appropriate printer control functions for an identified printer cartridge. The invention also has application where a user may wish to purposely depart from normanilly nonimal printer control functions for a particular purpose. For example, with a mechanical operation of the printer impaired, the user may prefer to implement a higher impact force than would normally be nominal. This can be done by a variety of processes, including removing the resistive label and replacing it with a different label so that results in the application of a higher impact force. As such, the resistive label may serve as a physical variant to control than to implement different control functions in accordance with predefined operational profiles.
[0046] [0046]FIG. 7 illustrates the method of use for the basic circuitry illustrated in FIG. 4 a . First, an ink cartridge is installed into the printer (step 71 ). When the ink cartridge is so installed, the resistive valve of its resistive ink identifier is sensed (step 73 ). The printer controller responds to the sensed resistive valve by regulating printing (step 75 ). In this embodiment, the resistive valve of the resistive ink identifier could be used, for instance, to represent a relative density of the ink on the ink ribbon of the ink cartridge. If the density was relatively high, the printer controller could respond to the sensed resistive valve by causing the pins of the print head to strike with less force, i.e. a shorter pulse width. Conversely, if the density was relatively low, the printer controller would respond to the sensed resistive valve by causing the pins of the print head to strike with more force. Accordingly, a uniform darkness of printed characters would be achieved by the system no matter what type of print cartridge was installed.
[0047] [0047]FIG. 8 illustrates a basic method of use for the circuitry illustrated in FIG. 4 b . As in the previous method, an ink cartridge is installed *(step 71 ) and the resistive valve of the resistive ink identifier on the ink cartridge is sensed (step 73 ). However, in this method a memory is used to correlate the sensed resistive valve with printer control data in the memory (step 77 ). The correlated printer control data and/or operational routines are input to the printer controller (step 79 ) which then regulates printing in response to the received input (step 75 ). In this embodiment, the resistive valve of the resistive ink identifier maybe be used to represent, for instance, a make or model of the print cartridge. The memory would then include information on an a variety of characteristics of such make and mode, for instance the length of the ribbon or the density of ink on the ribbon, stored as printer control data. The printer controller would respond to this printer control data and/or corresponding operational routines by regulating printing accordingly. The strike force of the pins on the pin head could be increased or decreased, the rate at which the ribbon was cycled through eh ink cartridge could be increased, or a number of other functions my be affected.
[0048] [0048]FIG. 9 illustrates a method of implementing the invention in relation to the circuitry illustrated in FIG. 4 b First, the ink cartridge is installed into the printer (step 71 ). If no valve is sensed, the printer operates in accordance with default parameters where a resistive valve of the resistive ink identifier is sensed (step 73 ), the sensed resistive valve is correlated to information set in memory (step 81 ). The information, which may include data and/or operational routines is used to define and implement a pulse width to be employed when energizing the coils of the striker (see FIG. 5) In response to this information, the printer controller regulates printing (step 75 ). As printing continues, the valve is increased (step 83 ). A counter increments the number of key strokes and that data is used, e.g. combined with the operational routines, to redefine, e.g. increase the pulse width, to increase impact force, the redefined pulse width and any other redefined parameters maybe stored in memory (step 81 ). The result is that the printer prints more and more, the pulse/width impact force increases accordingly and the striker is thereby caused to strike with a gradually increasing amount of force.
[0049] As printing is done, the amount of ink available in an ink cartridge is gradually depleted. However, much ink is remaining in the ink cartridge, it is distributed\more or less evenly over the ink ribbon. Thus, if less ink is left then the relative density of ink on the ribbon is lower. As a result, in prior art printers, as the ink is depleted the characters printed on a document to be printed grow steadily less dark. Steadily increasing the force with which the striker strikes in accordance with this embodiment of the present invention counteracts with this trend and ensures that the characters printed by the printer continue to be satisfactorily dark.
[0050] The system may comprise additional elements intended to provide further functionality. For instance, an alarm maybe in electrical communication with the memory. The alarm is operative to generate an alarm when data stored in the memory indicates that a relatively low amount of ink is left in the ink cartridge. Likewise, the system could comprise a display operative to display the amount of ink left in the ink cartridge. Alternatively, the printer controller could be configured to automatically cease functioning when the amount of ink left in the ink cartridge reached a selected threshold level.
[0051] It is understood that although the above represents several embodiments of the invention, the invention may take a still wider variety of embodiments intended to effect alternate designs or additional features. For instance, the force with which the striker strikes could be modulated by means of varying pulse amplitude instead of pulse width. Such embodiments are within the scope and spirit of the present invention. | A method and apparatus are provided for adaptively controlling printer functions of a dot matrix printer in response to sensing the type of printer ink cartridge being used. An identifying resistive value is applied to surface of the cartridge and installed within the printer. The printer includes contacts that include sensors and sensor circuitry useful to detect a presence of the resistive indicator and the resistive value thereof. The sensed resistive value is used to directly control printer functions, and/or to access stored data or printer control routines specific to the type of cartridge, or desired performance characteristics. Stored information, which may be appended by other sensed information such as printer usage data, is used to selectively regulate printer operation to achieve maximum efficiency and performance from the particular ink cartridge. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119 from U.S. Provisional Application Ser. No. 60/873,796 (filed Dec. 7, 2006), the disclosure of which is incorporated by reference herein for all purposes as if fully set forth.
TECHNICAL FIELD
This process relates to use of reactive diluents in the preparation of addition polymers, and to addition polymers so prepared and their use in high solids crosslinkable coating compositions, especially coatings useful for finishing automobile and truck exteriors.
BACKGROUND OF THE INVENTION
Most coatings used for finishing automobile and truck exteriors contain one or more film-forming polymers, optional crosslinking agents, and volatile organic solvents. The presence of volatile organic solvents is of concern, however, because they form the bulk of the emissions produced during application and curing of the coating composition which need to be controlled due to governmental regulations. Accordingly, there have been many attempts to reduce the emissions or VOC (volatile organic content) of such coatings.
One avenue for reducing regulated emissions has been to use waterborne coatings. While waterborne coating compositions offer lower emissions, they still contain significant amounts of organic co-solvent, and also have more elaborate and expensive handling and application requirements.
Powder coatings also have very low organic emissions but require complete reinvestment in the paint facilities and to date have not exhibited the appearance and other properties desired.
Another avenue for reducing regulated emissions has been to increase the solids content of solvent borne liquid coatings. The solids content of solvent borne liquid coatings can be increased by several methods, such as the use of lower molecular weight polymers or oligomers, and by using less organic solvent. The advantages of this approach include the exceptional appearance, durability and properties of such systems and the ability for them to be used in a current automotive plant with little or no change in facilities. At some point, however, the polymer solution becomes too viscous. This causes major problems with handling during manufacturing and also with the ability to spray or otherwise apply the coating onto the motor vehicle, thus requiring added solvent that increases the undesirable VOC content.
Another way to attain higher solids is to use reactive diluents, such as ethylene glycol or glycerol, in the final paint to keep the spray viscosity within acceptable limits. In these coatings, however, the film-forming polymer must be stripped of environmentally adverse hydrocarbon solvents that are used in the polymer synthesis before being introduced in the coating. The stripping step adds complexity, time and expense to the polymer synthesis and is therefore undesirable.
The object of the present invention is to provide an alternative to conventional environmentally hazardous organic liquid carrier solutions to attain high solids (low VOC) paints that can be applied with relative ease.
SUMMARY OF THE INVENTION
In one aspect, the present invention is a process for producing a polymer, said process comprising the step: polymerizing at least one ethylenically unsaturated monomer in the presence of a catalyst and a liquid carrier, wherein said liquid carrier is a reactive diluent, said reactive diluent having at least two reactive sites.
In another aspect, the present invention is a composition comprising;
(a) at least one ethylenically unsaturated monomer; (b) at least one reactive diluent; and (c) at least one catalyst suitable to catalyze the polymerization of said ethylenically unsaturated monomer;
wherein said reactive diluent is selected from selected from the group consisting of alkoxy silanes, alkoxy silicates, amide acetals, ketimines, cyclic carbonates, orthoesters, spiro-orthoesters, bicyclic orthocarbonates, or a combination thereof.
DETAILED DESCRIPTION
In one embodiment, the present process provides a means for producing addition polymers using reactive diluents as the liquid carrier rather than using conventional organic solvents as the liquid carrier, permitting the attainment of high solids (low VOC) paints with viscosity low enough for application using standard methods, such as, spraying, brushing, roller coating, dipping, etc. Preferably, the polymers produced are (meth)acrylic polymers which, when used herein, means that the polymers produced contain at least 50 percent by weight of (meth)acrylate monomers. The (meth)acrylic polymers preferably contain at least one crosslinkable functional group per molecule. Suitable crosslinkable functional groups can be chosen from hydroxyl, silane, epoxide, carboxyl, anhydride, isocyanate, carbamate, amine, or a combination thereof.
The term “(meth)acrylate” or “(meth)acrylic” means methacrylate or acrylate and can be used to describe both monomers and/or polymers.
As used herein, “reactive diluents” shall mean compounds or materials capable of functioning as solvent for the components of an addition polymerization process of the present invention, wherein said compounds or materials do not react to any substantial degree with the monomers used or polymer formed during the addition polymerization process, but wherein said compounds or materials have functionality that can be reacted subsequent to the addition polymerization process in the presence of the monomer or polymer. Preferably, reactive diluents of the present invention act as a solvent for both the monomers and for the polymer produced.
Reactive diluents of the present invention have at least two reactive sites that can react with a crosslinking agent to form part of a growing polymer chain and/or polymer network, in the case of a crosslinkable coating composition. The reactive sites on the reactive diluent may be masked or unmasked. A masked site is one that needs to undergo a chemical transformation, such as hydrolysis, to ‘expose’ the reactive site. Examples of ‘masked’ reactive diluents include amide acetals, ketimines, cyclic carbonates, orthoesters, spiro-orthoesters, and bicyclic orthocarbonates. An unmasked reactive site is one that can undergo a condensation reaction without any such transformation. An example of a masked reactive site is found in the spiro-orthoesters that can undergo hydrolysis to expose hydroxy groups. An unmasked reactive site is one such as an alkoxy silane. In the presence of water and an acid catalyst, such molecules can self-condense or can react with other functional groups present in the composition.
As indicated above, reactive diluents suitable for use herein can function as a solvent in the polymerization reaction of the selected monomers and do not substantially react with functional groups on the monomers/polymer during polymerization or interfere with the polymerization. Therefore, the reactive diluents should be carefully chosen so that they substantially do not react with the crosslinkable functional groups present in the polymer. The reactive diluent should be selected such that it does not catalyze either the polymerization or any crosslinking reactions. While it is desirable that no reaction between the diluent and the monomer or polymer component should occur, it is understood that minor side reactions may occur between the diluent and the functional groups on the monomer/polymer during polymerization, depending in part on the choice of diluent and polymerization components. Minor side reactions can be acceptable, although not preferred because it is desirable not to build additional viscosity and molecular weight that would result from substantial reaction between the monomer or polymer component and the reactive diluent. By “minor side reactions” or “substantially do not react” it is meant that less than 5 wt % of the diluent, by weight of the total diluent, reacts with the monomer or polymer component. Preferably less than 2 wt % of the diluent reacts with the monomer or polymer, more preferably less than 1 wt %. It is most preferred to have 0 wt % of the diluent react with the monomer and/or polymer.
Various types of polymerizations can be carried out using the disclosed process, such as free radical, anionic, group transfer and atom transfer radical polymerization reactions. Free radical polymerization reactions are generally preferred. Reaction temperature suitable for use in the present method are within the range of about 50° C. to 200° C., preferably in the range of about 70 to 160° C. The reaction is also typically carried out under atmospheric pressure. Advantageously, the disclosed process does not require the use of volatile organic solvents, while still being able to maintain the low viscosities desired for coating formulations.
The polymers produced by this process include acrylic polymers and copolymers, styrenated acrylic copolymers, styrene polymers and copolymers, vinyl acetate polymers and copolymers, and the like. Dispersed gelled acrylic polymers and copolymers can also be made using this process. These polymers are commonly referred to as non-aqueous dispersed polymers or NAD polymers. One method of preparing NAD polymers is to form a macromonomer that acts as a polymeric stabilizer component when it is subsequently chemically grafted to a crosslinked core. The linear stabilizer components are soluble in the organic liquid used to form the NAD while the core is insoluble in this liquid.
The term “condensation polymerization” or “condensation reaction” shall mean, for the purposes of the present invention, a reaction between two functional groups wherein a new chemical bond is formed, such as the reaction between an isocyanate functionality and a hydroxy or amine group; the reaction of a melamine with a hydroxy or an amine group; the reaction of an epoxy group with a carboxyl group or an amine group. The self-condensation of alkoxysilanes would be included in this definition, as would the self-condensation of alkoxysilicates.
When a polymerized mixture is used as a coating, the reactive diluent can react with itself and/or one or more film-forming polymers and/or crosslinking agents in the coating during the curing process, so as to become a permanent part of the coating film applied to a substrate. Several classes of reactive diluents have been identified. In some cases, the reactive diluent can undergo condensation polymerization reactions under the influence of heat and/or a catalyst. In other cases, the reactive diluent must be transformed, generally by undergoing a hydrolysis reaction, to reveal the crosslinkable functional groups of the reactive diluent. This hydrolysis reaction can take place by contacting the reactive diluent with a sufficient amount of water and/or a catalyst. In one embodiment, water vapor in the air can be sufficient to hydrolyze the reactive diluent.
In general, the monomers comprise about 20 percent to 90 percent by weight based on the weight of the monomers and the reactive diluent. Preferably, the monomers comprise 25 percent to 85 percent by weight based on the weight of the monomers and the reactive diluent, more preferably from about 50 to 75 percent by weight based on the weight of the monomers and the reactive diluent.
It is preferred that the ethylenically unsaturated monomers be a mixture, preferably including at least two different (meth)acrylic monomers. The present process can be applied to the preparation of copolymers from mixtures of two or more (meth)acrylic monomers. In another embodiment mixtures of at least one (meth)acrylic monomer and at least one non-(meth)acrylic monomer such as a styrenic monomer may be polymerized in accordance with the present process.
The term “(meth)acrylic monomer” as employed herein includes acrylic or methacrylic acid, esters of acrylic or (meth)acrylic acid and derivatives and mixtures thereof, such as but not limited to (meth)acrylamides and (meth)acrylonitriles. Individually, they are referred to as “(meth)acrylic” monomers. Examples of suitable (meth)acrylic monomers are (meth)acrylate esters such as alkyl (meth)acrylates that have 1-18 carbon atoms in the alkyl group such as methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, n-butyl (meth)acrylate, isopropyl (meth)acrylate, isobutyl (meth)acrylate, t-butyl (meth)acrylate, n-amyl (meth)acrylate, n-hexyl (meth)acrylate, isoamyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, nonyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, and the like. Cycloaliphatic (meth)acrylates also can be used such as trimethylcyclohexyl (meth)acrylate, t-butylcyclohexyl (meth)acrylate, cyclohexyl (meth)acrylate, isobornyl (meth)acrylate, and the like. Aryl (meth)acrylates can also be used such as benzyl (meth)acrylate, phenyl (meth)acrylate, and the like.
Other suitable (meth)acrylic monomers include (meth)acrylic acid derivatives such as: (meth)acrylic acid and its salts, (meth)acrylonitrile, (meth)acrylamide, N-alkyl (meth)acrylamide, N,N-dialkyl (meth)acrylamide, N-phenyl-(meth)acrylamide and (meth)acrolein.
Apart from (meth)acrylic monomers, other polymerizable non-(meth)acrylic monomers that can be used for forming the polymer include vinyl aromatics such as styrene, alpha-methyl styrene, t-butyl styrene, vinyl toluene; vinyl acetate, and vinyltrimethoxy silane, or a combination thereof. When used, non-(meth)acrylic monomer(s) are typically present at a level of at least 1 percent and up to about 20 percent by weight of the total monomer mixture, and the balance (meth)acrylic monomers.
Functionalized versions of any of the monomers listed above may be used in the preparation of the polymer to impart crosslinkable functionality to the polymer. The functional groups on such monomers should be capable of crosslinking with themselves or with other film-forming polymers. Typically crosslinking functional groups include hydroxyl, silane, epoxide, carboxyl or other acid, anhydride, isocyanate, carbamate, and amine groups. Combinations of monomers containing the above-mentioned crosslinking functional groups are also suitable, provided that they do not react with each other under polymerization and storage conditions. While practicing this approach, functional monomers that are reactive under addition polymerizing conditions with the reactive diluents should be avoided.
Typical ethylenically unsaturated monomers that can be used to introduce crosslinking functional groups into the polymer during its polymerization include epoxy functional acrylic monomers such as glycidyl (meth)acrylate; carboxyl or other acid functional monomers such as (meth)acrylic acid, maleic acid, itaconic acid, styrene sulfonic acid, acrylamido methyl propane sulfonic acid, vinyl phosphonic or vinyl phosphoric acid; hydroxy functional acrylic monomers such as hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, hydroxybutyl (meth)acrylate; amine functional monomers such as t-butyl amino ethyl (meth)acrylate, dimethyl amino ethyl (meth)acrylate, aminoalkyl (meth)acrylates; isocyanate functional monomers such as isocyanatoethyl (meth)acrylate; carbamate functional (meth)acrylic monomers such as 2-(methoxycarbonyl)aminoethyl (meth)acrylate, 2-(cyclohexoxycarbonyl)aminoethyl (meth)acrylate and 2-propenyloxyethyl carbamate; silane functional (meth)acrylic monomers such as vinyl or (meth)acrylic alkoxy silane monomers such as vinyl trimethoxy silane, vinyl methyldimethoxy silane, vinyl triethoxy silane, and vinyl tris (2-methoxyethoxy) silane, gamma-(meth)acryloxy propyl trimethoxysilane, gamma-(meth)acryloxy propyl trimethoxysilane, and gamma-(meth)acryloxypropyltris(2-methoxyethoxy) silane; and the like.
When used, the functional group containing monomers are typically present at a level of at least 2 percent and up to 40 percent by weight of the total monomer mixture.
Other possibilities for introducing functional groups into the polymer, such as by post reaction of an epoxy group with water or acid to form a hydroxy group, will be apparent to persons skilled in the art. This type of post-reaction to form a functional group should be undertaken with care so as not to cause a condensation reaction with the reactive diluent.
The selection of a particular reactive diluent and its level of addition are made based on the monomers selected, the desired applications for the polymer produced and also to assist in controlling reaction parameters. Suitable reactive diluents for the present process should of course at least be capable of dissolving the monomers and/or polymer formed therefrom. In general, it is preferred to use as little reactive diluent as possible so as to minimize the formation of by-products and contaminants.
Reactive diluents which are suitable for use in the present process include materials that contain at least one, preferably at least two reactive groups that do not react with the monomer or the polymer during the addition polymerization, but that are capable of later reacting through condensation reaction with a crosslinking agent and/or other film-forming polymers present in the coating composition during cure. Multi-functional reactive diluents having from about 2 to 25 condensation reactive sites are generally preferred. The reactive diluent may be a compound or a polymeric material. If the reactive diluent is polymeric, it is preferably a low molecular weight polymer, most preferably, a liquid oligomeric material.
The reactive diluents according to the present disclosure include alkoxy silanes, alkoxy silicates, amide acetals, ketimines, cyclic carbonates, orthoesters, spiro-orthoesters, bicyclic orthocarbonates, or a combination thereof.
Suitable alkoxy silane functional reactive diluents contain 2 or more hydrolyzable silane groups such as, dialkoxy diakylsilanes or trialkoxy alkylsilanes. Examples of these include but are not limited to alkoxysilated 4-vinyl cyclohexene, alkoxysilated limonene, 5-(2-trimethoxysilylethyl)-trialkoxysilylnorbornane, 1,4-bis[3-trialkoxysilylpropyloxymethyl]cyclohexane, and other silane containing compounds with more than one trialkoxysilyl group, disclosed in U.S. Pat. No. 5,719,251 which is herein incorporated by reference; 1,2-bis(trialkoxysilyl)ethane, 1,6-bis(trialkoxysilyl)hexane, 1,8-bis(trialkoxysilyl)octane, 1,4-bis(trialkoxysilylethyl)benzene, 1,5,9-tris(trialkoxysilyl)cyclododecatriene, 1,2,4-tris(2-trialkoxysilylethyl)cyclohexane, other silane containing compounds, with more than one trialkoxysilyl group, disclosed in U.S. Pat. No. 6,080,816 which is herein incorporated by reference; bis(3-trialkoxysilyl-2-hydroxypropyl) succinate, other silane containing compounds, with more than one trialkoxysilyl group, disclosed in U.S. Pat. No. 6,268,456 which is herein incorporated by reference; an oligomer produced when bis(trialkoxysilyl)-limonene is contacted with water, other silane containing compounds, with more than one trialkoxysilyl group, disclosed in U.S. Pat. No. 6,329,489 which is herein incorporated by reference.
In the presence of water (i.e., atmospheric moisture) and acid catalyst alkoxysilanes can subsequently react after application on a substrate with functional groups such as hydroxyl groups in a polymer to crosslink the polymer or with a hydroxyl group-containing reactive diluent to form polymer that can crosslink. In addition alkoxysilanes are capable of self-condensation. In either case the resulting product is a silicate bond so that either a polysilicate is formed or an alkyl bridged silicate crosslink which are both known to provide durable, tough and weatherable coating compositions.
Alkoxy silicate functional reactive diluents can also be used. These include but are not limited to tetraethyl silicate, hexaethyl disilicate and other oligomers of tetraethyl silicate, tetramethyl silicate, hexamethyl disilicate and other oligomers of tetramethylsilicate, 1,2-ethanediyl hexamethyl disilicate, 1,2-propanediyl hexamethyl disilicate, 1,3-propanediyl hexamethyl disilicate, 1,4-butanediyl hexamethyl disilicate, 1,4-cyclohexylmethylenediyl hexamethyl disilicate, 1,2,6-hexanetriyl trisilicate. Alkoxy silicates, in the presence of water and acid catalyst, can react with hydroxyl groups, can self condense, and can react with alkoxysilanes. Alkoxy silicates produce polymers and crosslinks similar to alkoxy silanes and are useful because they are lower cost, however they are less hydrolysis resistant, an important consideration in outdoor exposure, particularly resistance to acid rain which leads to a phenomenon called acid etch and is of particular importance for clear coats used for high quality automotive finishes. Often a useful balance of properties can be found in blends of silicates and silanes.
Amide acetal reactive diluents can also be used. Amide acetals are compounds according to the structural formula (I);
wherein R 1 , R 2 , R 3 , and R 4 each are independently selected from the group of C(R 6 ) 2 and C(R 6 ) 2 C(R 6 ) 2 ; R 5 is selected from H and an optionally substituted alkyl group having 1 to 20 carbons; and each R 6 is independently chosen from H, optionally substituted alkyl group having from 1 to 20 carbons, optionally substituted aryl groups having from 6 to 20 carbons, optionally substituted alkyl esters having from 1 to 20 carbons, or optionally substituted aralkyl groups having from 6 to 20 carbons.
These include but are not limited to 1-aza-(3,5,7-trimethyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(3,7-dimethyl-5-butyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(5-methyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(5-butyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(5-n-undecyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(5-(4-cyanobutyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(5-cyclooctyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(4-methyl-3-cyanopropyl)-4,6-dioxabicyclo[3.3.0]octane.
Once applied on a substrate the amide acetals can ring open in the presence of suitable catalyst and water to produce dihydroxy compound or a compound with a secondary amine and a hydroxy group or in most cases a blend of the two products depending on the structure of the amide acetal. The hydroxy groups can react with partially or fully alkoxylated melamine formaldehyde resin, polyisocyanates, alkoxy silanes, alkoxy silicates and anhydrides. The amine containing compounds can react with alkoxylated melamine formaldehyde resins, polyisocyanates, and epoxy resins. The above crosslinking agents can be combined as desired. Suitable results can also be obtained by employing combinations of crosslinking agents such as alkoxylated melamine formaldehyde resin and silane; alkoxylated melamine formaldehyde resin and polyisocyanate; polyisocyanate and epoxy; alkoxylated melamine formaldehyde resin, silane and silicate; melamine, silane and polyisocyanate.
One can combine an alkoxysilane functionality with a bicyclo amide acetal, for example 1-aza-(3-trimethoxysilylpropyl)-4,6-dioxabicyclo[3.3.0]octane, 1-aza-(3-triethoxysilylpropyl)-4,6-dioxabicyclo[3.3.0]octane to produce reactive diluents with multiple functionalities.
Ketimine reactive diluents can also be used. These include but are not limited to 1,3,3-trimethyl-N-(1,3-dimethylbutylidene)-5-[(1,3-dimethylbutylidene)amino]cyclohexane, sold commercially under the name Desmophen® LS 2965 by Bayer AG, Pittsburgh, Pa.; N1,N3-Bis(1,3-dimethylbutylidene)diethylenetriamine available commercially from Air Products of Allentown, Pa.; other ketimines disclosed in U.S. Pat. No. 6,605,688 herein incorporated by reference; ketimines disclosed in U.S. Pat. No. 6,297,320 herein incorporated by reference. Ketimines form amines when exposed to water and a suitable catalyst and the amines so formed can be reacted with polyisocyanates, to form polyureas; with polyepoxides to form hydroxy polyamines; and with melamines to form alkyl bridged condensed melamine polymer.
Cyclic monocarbonates and polycyclocarbonates are useful reactive diluents. Monocarbonates on ring opening form two hydroxy groups so they can react to form polymer, however polycyclocarbonates are favored because of their greater reactivity. Polycyclocarbonates of the present invention, can be but are not limited to:
where R in formula (II) denotes an organic linking group such as linear alkyl group with 1-18 carbon atoms; branched or cyclic alkylgroup with 3-18 carbon atoms; and aryl group with 6-18 carbon atoms.
Alcohols and polyols can be converted to carbonates by reacting with epichlorohydrin to produce an epoxy ether and subsequent reaction with carbon dioxide to convert the epoxy to carbonate functionality. Formula (III) illustrates this structure that is formed when using a diol;
where R denotes an organic linking group such as linear alkyl group with 1-18 carbon atoms; branched or cyclic alkylgroup with 3-18 carbon atoms; and aryl group with 6-18 carbon atoms. Many polyols can suitably be converted to polycarbonates useful as a reactive diluent.
Other useful polycarbonates can be obtained from epoxy compounds by reaction with carbon dioxide. Particularly useful epoxy compounds are oligomers containing glycidyl (meth)acrylate and compounds such as hydrogenated bisphenol A diepoxide.
Polycarbonates when subsequently reacted with polyamines produce hydroxyurethane polymer. If either the polycarbonate or formed polyamine has more than 2 functional groups, then such polymer can also crosslink. In addition the hydroxy group formed on ring opening of the carbonate ring after application on a substrate can react with melamine (e.g., partially or fully alkoxylated melamine formaldehyde resins); with polyisocyanate; and/or with polyanhydrides to produce crosslinked polymer.
Other protected hydroxyl compounds can be useful reactive diluents because they tend to lower viscosity because hydrogen bonding is minimized. Of particular utility among these compounds are bicyclic orthocarbonates, orthoesters, and spiro-orthoester functional compounds which are disclosed in U.S. Pat. No. 6,593,479, incorporated by reference herein.
Various methods can be employed to prepare spiro-orthoester compounds. One such method is the reaction of an epoxy-functional compound such as butyl glycidyl ether with a lactone such as caprolactone or butyrolactone. Alternatively, spiro-orthoester functional polymers can be prepared from epoxy-functional polymers, e.g., polyacrylates of glycidyl(meth)acrylate, using lactones, or by forming polylactones using monoepoxides. Again, use may be made of catalyst such as Lewis acid or Bronsted acids, preferably paratoluene sulfonic acid of BF 3 Et 2 O.
Many of these protected hydroxy compounds are useful as they do not produce volatile organic by-products that could contribute to VOC. Once applied to a substrate in the presence of moisture from the air and optionally provided with an acid catalyst, these protected hydroxyl compounds will be hydrolyzed and ring open to give polyhydroxy compounds that can be reacted with melamine to give bridged condensed melamines; with polyisocyanates to give polyurethane polymers; and with polyanhydrides to give polyesters.
As indicated above, the selection of the reactive diluents will vary depending on the monomers selected and the type of polymer intended to be produced. (Meth)acrylic polymer systems are of importance in automotive coating systems in use today at vehicle assembly plants and collision repair shops. The reactive diluents of the present process can be used to reduce the VOC of these coatings. Hydroxy functional (meth)acrylic film-forming polymers are perhaps the most common type of polymers in use. Also in use today is an acid etch resistant clear coating that contains silane functional acrylic polymers. Another commercially important coating is a dual silane/hydroxy acrylic polymer. All three of these film-forming polymers can be produced in the present reactive diluents that will lower the VOC of the coatings and help to make them more environmentally friendly.
Referring again to the polymerization process employing these reactive diluents, in a free-radical polymerization process, the type of polymerization catalyst suitable for use in the present process is known in the art to depend upon the desired temperature for the reaction. Suitable catalysts include azo and peroxide type initiators, chosen from but not limited to, the following: t-butyl peroxide, t-butyl peroxybenzoate, t-butyl peroctoate, cumene hydroperoxide, 2,2′-azobis(isobutyronitrile) (Vazo® 64 thermal initiator supplied by Du Pont Company, Wilmington, Del.); 4,4′-azobis(4-cyanovaleric acid) (Vazo® 52 thermal initiator supplied by Du Pont Company, Wilmington, Del.) and 2-(t-butylazo)-2-cyanopropane, benzoyl peroxide, or a combination thereof. It is preferred to add from about 0.1 to about 8.0 percent by weight of the monomer mixture of the polymerization catalyst. The choice of polymerization catalyst is important when choosing the reactive diluent. If a reactive diluent is chosen that is sensitive to acidic conditions, then care must be taken when using peroxide catalysts as the by-products of these materials are generally acidic in nature.
Where desired, a chain transfer agent may be employed in the present process. Chain transfer agents which are suitable for use in the above reaction include, but are not limited to, the following: dodecyl mercaptan, mercaptoacetic acid, mercaptopropionic acid, octyl mercaptan, 2-mercaptoethanol, and combinations thereof. Where employed, it is preferred to use an amount of chain transfer agent in the range of from about 0.5 to about 2.0 percent by weight of the monomer mixture of chain transfer agent.
It can be optional to add, in addition to the diluent, an organic solvent in the present process. Suitable organic solvents include aromatic solvents, aliphatic solvents, esters, glycol ethers, glycol ether esters, ketones and combinations thereof. Where employed, it is preferred to use an amount of organic solvent in the range of about 1 percent to about 20 percent by weight of the reaction mixture. It is, however, generally desired to keep the reaction free of organic solvent to achieve the maximum benefit of this process.
In one embodiment a batch polymerization process is employed for the addition polymerization reaction. The residence time for such batch processes is commonly in the range of about 1 hour to about 10 hours. In a second embodiment the addition polymerization reaction may be conducted via the use of a continuous stirred tank polymerization process. The residence time for such continuous processes is commonly in the range of about 90 minutes to about 6 hours; with the preferred residence time being in the range of about 2 hours to about 3 hours. In still another embodiment a fully continuous process can be used where the residence time is in the range of 0.5 minutes to 10 minutes. The polymerization process described herein comprises polymerizing at least one ethylenically unsaturated monomer, at least one reactive diluent, and at least one catalyst suitable to catalyze the polymerization of the monomer is run at a temperature that is sufficient to cause polymerization of the monomers in the presence of the catalyst, typically from about 50° C. to about 200° C. Optionally, a suitable chain transfer agent and/or a suitable organic solvent may be used in the polymerization.
It is well within the ability of one skilled in the art to produce coatings from these polymer compositions that approach 100 percent by weight total solids and have a VOC approaching 0 lbs/gal (0 kg/L). Coating compositions made from addition polymers produced by the disclosed process contain relatively small percentages of volatile organic solvents, preferably less than 10 percent non-volatiles.
In another embodiment, the present invention is a composition comprising at least one ethylenically unsaturated monomer; at least one reactive diluent; and at least one catalyst suitable to catalyze the polymerization of said ethylenically unsaturated monomer; wherein said reactive diluent is selected from selected from the group consisting of alkoxy silanes, alkoxy silicates, amide acetals, ketimines, cyclic carbonates, orthoesters, spiro-orthoesters, bicyclic orthocarbonates, or a combination thereof.
The addition polymers produced can be combined with at least one crosslinking agent to form the coating composition. The crosslinking agents are chosen from the group of polyisocyanates, melamine resins, amino resins, blocked polyisocyanates, or a combination thereof and are well known to those skilled in the art. Also, the crosslinking agent can be chosen from polyepoxides, polycarboxylates, polyamines, polyols, or a combination thereof. It may also be possible to use as the crosslinking agent, a moiety that contains more than one type of crosslinking moiety. For examples, N,N-diethanol amine contains both amine and hydroxyl functionality and may serve as a crosslinking agent. Care must be taken not to introduce combinations of crosslinking moieties that are incompatible with one another, for example, acid groups and epoxide groups will react with one another under certain conditions.
As appreciated in the art, the exact components and properties of components desired for any coating application can vary and, therefore, routine experimentation may be required to determine the optional components and proportions of components for a given application and desired properties.
The polymers and copolymer solutions produced herein are particularly useful as binders in clear coat finishes that are applied over a colored basecoat, in order to form an attractive color-plus-clear composite finish over automobile and truck exteriors.
The following Examples illustrate the process. All parts and percentages are on a weight basis unless otherwise indicated. All molecular weights disclosed herein are determined by GPC (gel permeation chromatography) using polymethyl methacrylate as the standard.
EXAMPLE 1
Preparation of an Amide Acetal Reactive Diluent
1-Aza-(3,7-dimethyl-5-n-undecyl)-4,6-dioxabicyclo[3,3,0]octane
Undecyl nitrile (92.8 g, 0.509 mol), diisopropanolamine (67.7 g, 0.508 mol) and zinc acetate (1.87 g, 0.010 mol) were contacted in a three-neck flask equipped with stirrer and an input for nitrogen. The reactor contents were heated to and held at 130° C. for 5 hours and then at 150° C. for an additional about 18 hours under a nitrogen atmosphere.
The reaction mixture was cooled to room temperature. The resulting solution had a Pt—Co# of 81 and gas chromatographic analysis indicated a conversion of 82.2% of the nitrile to the desired product.
The color analyses were done using a UV spectrophotometer and ASTM method D5386-93b. The result is given as a Pt—Co number and is an indication of the yellowness of the sample. The lower the number, the less yellow is the sample. A value of zero is comparable to the color of pure water.
EXAMPLE 2
Preparation of a Hydroxyl Functional Acrylic Polymer in Reactive Diluent
Amide Acetal
To a 5-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet and heating mantle was added 800 grams dodecane amide acetal (1-aza-(5-n-undecyl)-4,6-dioxabicyclo[3.3.0]octane prepared above. This mixture was agitated and heated to 155° C. While maintaining the batch at 155° C., a mixture of 260 grams 1,6-hexanediol diacrylate, 1440 grams 2-ethyl hexyl acrylate, 300 grams hydroxyethyl methacrylate, 20 grams t-butylperoxy acetate was added over a 300 minute period. Then the reaction mixture was held at 155° C. for an additional 60 minutes. The weight solids of the resulting polymer solution was 94.3%.
EXAMPLE 3
Preparation of a Hydroxy Functional Acrylic Polymer in Reactive Diluent
Amide Acetal
To a 1-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet and heating mantle was added 200 grams dodecane amide acetal (1-aza-(5-n-undecyl)-4,6-dioxabicyclo[3.3.0]octane. This mixture was agitated and heated to 120° C. While maintaining the batch at 120° C., a mixture of 125 grams styrene, 215 grams butyl methacrylate, 160 grams hydroxyethyl acrylate, 30 gms t-butylperoxy octoate was added over a 300 minute period. Then the reaction mixture was held at 120 C for an additional 60 minutes. The weight solids of the resulting polymer solution was 90.0%.
EXAMPLE 4
Preparation of a Silane Functional Macromonomer in Silane Reactive Diluent
To a 5-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet and heating mantle was added 92.4 grams 2-ethyl hexylmethacrylate, 46.2 grams gamma-methacryloxypropyl trimethoxysilane, 92.39 grams isobutyl methacrylate and 740.3 grams of a reactive diluent (a mixture of 1-trimethoxy ethyl silyl-3-trimethoxysilyl cyclohexane and 1-trimethoxy ethyl silyl-4-trimethoxysilyl cyclohexane). This mixture was agitated and degassed by bubbling nitrogen through the solution for 30 minutes. Then the mixture was heated to 70° C. After the mixture had stabilized at 70° C., the following solution was added as a shot: 115 grams ethyl acetate, 0.08 grams Co(II)DPG and 2.9 grams Vazo 52. After the batch stabilized at 70 C, a mixture of 831.5 gms 2-ethylhexyl methacrylate, 415.7 grams gamma-methacryloxypropyl trimethoxysilane, 831.5 grams isobutyl methacrylate, 46.4 grams heptane was added over a 180 minute period. Simultaneously with this monomer mixture, a mixture of 250 grams ethyl acetate and 26.1 grams Vazo® 52 were fed to the reactor over 330 mins. Then the reaction mixture was held at 70 C for an additional 30 minutes. After the hold, a mixture of 30 grams heptane and 1 gm. t-butyl peroxyoctoate was feed to the reactor over 60 mins. After completion of this feed the reaction mixture was held at 70 C for an additional 30 mins. The weight solids of the resulting polymer solution was 69.3%. Number average molecular weight of the polymer was 52,305 and polydispersity was 2.5, determined by GPC.
EXAMPLE 5
Preparation of Silane and Hydroxyl Functional NAD in Amide Acetal Reactive Diluent
To a 5-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet and heating mantle was added 761.0 grams of the macromonomer prepared in Example 4 and 358.0 grams of the same reactive diluent as used in Example 4. This mixture was agitated and degassed by bubbling nitrogen through the solution for 15 minutes. The batch was then brought to 70° C. and a mixture of 140.4 grams hydroxypropyl acrylate, 396.9 grams methyl methacrylate, 109.6 grams methyl acrylate, 6.6 grams styrene and 3.4 grams allyl methacrylate was added to the reactor over a 210 minute period. A mixture of 17.9 grams ethyl acetate, 55 grams mineral spirits and 10.1 grams Vazo 52 was added simultaneously with the previous mixture over a 210 minute period. Then the reaction mixture was held at 70° C. for an additional 120 minutes. The weight solids of the resulting polymer solution was 68.5% and the Brookfield viscosity measured at 25° C. was 650 centipoise using a #3 spindle at 5 rpm.
EXAMPLE 6
Preparation of an Acrylic Polymer in Bicyclic Amide Acetal Reactive Diluent
To a 2-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet, and a heating mantel was charged 211.56 grams of dodecane amide acetal. The reaction was heated to 100° C. A mixture of 391.39 grams isobornyl acrylate and 137.52 grams 2-hydroxyethyl methacrylate was fed to the reaction over a 4-hour period. A mixture of 13.22 grams Vazo 67 initiator in 52.89 grams of the dodecane amide acetal was added concurrently with the monomer charge. The initiator was fed over a 5 hour period, keeping the reaction at 100° C. When the initiator charge was complete, the reaction was allowed to cool to room temperature and 197.0 grams of acetone was added to the mixture. The weight solids of the resulting polymer solution was 81.3% and the Gardner-Holdt viscosity was x. The polymer had a number average MW of 4919 and a weight average MW of 11531.
EXAMPLE 7
4-Ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane
Trimethylolpropane (268.0 g, 2.0 mol), triethyl orthoacetate (356.4 g, 2.20 mol) and toluene sulfonic acid (4.0 g) were charged into a oven dried round bottom flask equipped with a stirring bar, distillation head and under nitrogen. The resulting solution was heated until the theoretical amount od ethanol was collected. The reaction was cooled to room temperature. Fractional vacuum distillation afforded the product as a water clear liquid, boiling point 62.8-71.2° C. at 0.78-1.80 torr. Yield: 276.0 g (87.3%)
EXAMPLE 8
Preparation of 3,9-Dibutyl-3,9-Diethyl-1,5,7,11-tetraoxaspiro[5,5]undecane
In a three neck 500 mL RB flask equipped with a reflux condenser, a Dean-Stark trap and under nitrogen, 2-butyl-2-ethyl-1,3-propanediol (35.33 g, 0.22 mol) and toluene (350 mL) were added. The resulting mixture was heated to reflux for 2 h. The resulting solution was cooled to RT and 4-ethylbenzenesulfonic acid (0.35 g) and tetraethylorthocarbonate (21.3 g, 0.11 mol) were added. The reaction mixture was heated to reflux and the azeotropic solution collected in the Dean-Stark trap. The azeotropic mixture was measured and removed from the trap and poured into brine. The toluene phase was separated giving ˜22 mL of ethanol, via shaking with brine. TLC of the reaction mixture showed the complete conversion of the starting diol. To the cooled reaction mixture was added triethylamine (3.0 mL). The reaction mixture was then concentrated at reduced pressure (rotovap) and then dried under vacuum. This crude material was then fractionally vacuum distilled and the fraction boiling at 170-18° C. at 1.8 torr and collected (24.72 g) as a water white clear liquid.
EXAMPLE 9
Ketimine Used
Purchased from Bayer
Ketimine from isophorone diamine and 2 moles of methyl isobutylketone (1,3-dimethyl-butylidene)-{3-[(1,3-dimethyl-butylidene)-methyl]-3-methyl-cyclohexyl}amine-4-ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane (available from Bayer as Desmophen IS-2965A).
EXAMPLE 10
Preparation of an Acrylic Polymer in Bicyclic Orthocarbonate Reactive Diluent
To a 2-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet, and a heating mantel was charged 211.56 grams of 3,9-dibutyl-3,9-diethyl-1,5,7,11-tetraoxaspiro[5,5]undecane. The reaction content was heated to 100° C. A mixture of 391.39 grams isobornyl acrylate, 137.52 grams 2-hydroxyethyl methacrylate, 10.58 grams Vazo 67 initiator and 42.31 grams 3,9-dibutyl-3,9-diethyl-1,5,7,11-tetraoxaspiro[5,5]undecane was added over a 4-hour period. Then a solution of 2.64 g of Vazo 67 initiator, 10.58 g 3,9-dibutyl-3,9-diethyl-1,5,7,11-tetraoxaspiro[5,5]undecane, and 36.78 grams of acetone was added over one hour at 100° C. After completion the reaction solution was stirred at 100° C. for 30 minutes. The reaction was cooled to room temperature and 299.64 grams of acetone added to give a Gardner-Holdt viscosity of Y, with a solid content of 68.36. At this point the batch is close to the gel point.
EXAMPLE 11
Preparation of an Acrylic Polymer in Bicyclic Orthoester Reactive Diluent
To a 2-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet, and a heating mantel was charged 211.56 grams of 4-ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane. The reaction content was heated to 100° C. A mixture of 391.39 grams isobornyl acrylate, 137.52 grams 2-hydroxyethyl methacrylate, 10.58 grams Vazo 67 initiator and 42.31 grams 4-ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane was added over a 4-hour period. Then a solution of 2.64 grams of Vazo 67 initiator, 10.58 grams 4-Ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane, and 36.78 grams of acetone was added over one hour at 100° C. After completion the reaction solution was stirred at 100° C. for 30 minutes. The reaction was cooled to room temperature and 156.64 grams of acetone added to give a Gardner-Holdt viscosity of V, with a solid content of 80%.
EXAMPLE 12
Preparation of an Acrylic Polymer in Ketimine Reactive Diluent
To a 2-liter glass flask equipped with an agitator, thermometer, water condenser, nitrogen inlet, and a heating mantel was charged 211.56 grams of the ketimine from isophorone diamine and 2 moles of methyl isobutylketone (1,3-dimethyl-butylidene)-{3-[(1,3-dimethyl-butylidene)-methyl]-3-methyl-cyclohexyl}amine-4-ethyl-1-methyl-2,6,7-trioxa-bicyclo[2.2.2]octane (available from Bayer as Desmophen IS-2965A). The reaction content was heated to 100° C. A mixture of 391.39 grams isobornyl acrylate, 137.52 grams 2-hydroxyethyl methacrylate, 10.58 grams Vazo 67 initiator and 42.31 grams Desmophen IS-2965A was added over a 4-hour period. Then a solution of 2.64 grams of Vazo 67 initiator, 10.58 g Desmophen IS-2965A, and 36.78 grams of acetone was added over one hour at 100° C. After completion the reaction solution was stirred at 100° C. for 30 minutes. The reaction was cooled to room temperature and 156.64 grams of acetone added to give a Gardner-Holdt viscosity of V, with a solid content of 80%.
COATING EXAMPLE 1
In a glass jar 50.01 grams of the material from example 6 was combined with 8.75 of propylene glycol monomethylether acetate, 2.78 grams of a 10% dibutyl tin dilaurate solution in ethyl acetate, and 0.67 grams of a BYK 306 and 0.24 grams of Byk 361. To this was added 37.55 grams of a solution of 13.26 grams of Desmodur 3300 (hexamethylene diisocyanate trimer available from Bayer), 21.67 grams of Desmodur Z4470BA (isophorone diisocyanate trimer available from Bayer) and 2.63 grams diisobutyl ketone. This mixture was stirred stirred and then 0.22 grams of acetic acid was added and the mixture and stirred. The mixture was drawndown to give coatings of ˜2 mils in thickness. At one day the coating had a Fischercope hardness of 43 N/mm2, and a swell ratio of 1.58. At 30 days the Tg (at the midpoint) was 58 C and the gel fraction was 90%.
Film Preparation
The clearcoats were drawn down over Uniprime (ED-5000), TPO, using a 6 mil drawdown blade.
Micro-Hardness
The micro-hardness of the coatings was measured using a Fischerscope hardness tester (model HM100V). The tester was set for maximum force of 100 mN ramped in series of 50, 1 second steps. The hardness was recorded in N/mm 2 .
Swell Ratio
The swell ratio of the free films (removed from TPO) was determined by swelling in methylene chloride. The free film was placed between two layers of aluminum foil and using a LADD punch, a disc of about 3.5 mm diameter was punched out of the film. The aluminum foil was removed from either side of the free film. Using a microscope with 10× magnification and a filar lens the unswollen diameter (D O ) of the film measured. Four drops of methylene chloride were added to the film, the film was allowed to swell for a few seconds and then a glass slide was placed over it. The swell ratio was then calculated as:
swell ratio=( D S ) 2 /( D O ) 2 | The present process is directed to preparation of addition polymers in diluents that are subsequently reactive in coatings during cure, instead of in traditional hydrocarbon solvents. The polymers so prepared can be used as the main film-forming polymer in high solids coating compositions, especially those useful for finishing automobiles and truck exteriors. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation in part of applicants copending application Ser. No. 10/253,073, filed Sep. 23, 2002.
FIELD OF THE INVENTION
[0002] Safe, non irritating, non aqueous spray compositions administrable via the nasal cavity.
BACKGROUND OF THE INVENTION
DISCUSSION OF THE PRIOR ART
[0003] The use of nasal sprays to provide relief from the nasal stuffiness of colds and allergic rhinitis is widespread. Various sympathomimetic amines have been used to provide relief. Nasal decongestants stimulate the alpha-adrenergic receptors of the vascular smooth muscle. This constriction results in shrinkage of the engorged mucous membranes which promotes drainage; improves nasal ventilation and relieves the feeling of stuffiness.
[0004] Many decongestants are commercially available and are used to give various lengths of relief from 4 hours up to 12 hours. All of these decongestants are water soluble and are delivered in aqueous spray Systems.
[0005] The decongestant solutions are delivered by spray from either a flexible plastic container that produces a mist when squeezed or by a hand operated mechanical pump.
[0006] These aqueous sprays are wet, cold and drip from the nose. They are very uncomfortable to use. Since they are aqueous based and the nozzle is inserted in the nostril, bacterial contamination of the product easily occurs. Nasal sprays are difficult to preserve.
[0007] The mucous layer lining the epithelium represents a barrier to drug absorption along with mucociliary clearance mechanisms of the nose leads to short residence time of aqueous systems at the site of absorption which limits the systemic availability of the drug.
SUMMARY OF THE INVENTION
[0008] The invention is directed to compositions of incorporating an effective dosage of decongestant or other drug from a safe, non-aqueous, non-irritating, tastless and odorless liquid carrier system that delivers an extremely fine, non-dripping, warm, pleasant spray to the nasal cavity from either a squeeze bottle or pump spray system.
[0009] There is provided a non-aqueous liquid spray composition for a bioactive material comprising a pharmacologically acceptable non aqueous liquid carrier in which said bioactive material is directly insoluble, a pharmacologically acceptable water insoluble ester of a water soluble acid soluble in said carrier, a pharmacologically acceptable water soluble glycol soluble in said ester, a pharmacologically acceptable water soluble bio-active material soluble in said glycol but directly insoluble, that is to say cannot be directly dissolved in in said carrier.
[0010] The spray compositions of the present invention are produced by the sequential steps of dissolving the bio-active material in a glycol, dissolving the resultant solution in a water insoluble ester of a water soluble acid and dissolving said further resultant solution in a suitable carrier as discussed above.
[0011] The spray compositions of the present invention containing the appropriate bio-active material may be administered to a subject in need of same by spraying a pharmacologically effective amount of such a composition into the nasal cavity of said subject. This may be done using any spray method, such as using a pump spray device or a squeeze bottle spray, the latter being inexpensive and especially suitable.
[0012] The system of the present invention possesses several advantages over the aqueous nasal administration systems heretofore available. It provides a fine, warm, dripless, non-irritating spray, which, depending on the drug used, gives 4-12 hour decongestant relief. Because the system is non-aqueous, no preservatives are needed and the system will resist recontamination.
[0013] Furthermore because the system is anhydrous, it will wet out and cling to the mucous membrane of the nasal passages. Being water resistant, it will resist removal by the mucocillary clearance mechanism; thereby allowing more contact time at the site. The drugs will partition from the system and be adsorbed by the mucosa giving faster onset of action and greater symptom relief.
[0014] The system works exceptionally well with all commercially available spray systems. In fact, the efficacy of squeeze bottle system is comparable to the more expensive pump spray delivery.
[0015] All ingredients are safe for use in the nose. The esters and glycols used manifest a moisturizing effect which will keep the nasal tissues soft and supple thereby eliminating nasal dryness. In addition to the bio-active materials to be administered, the spray compositions may also include conventional additives such as essential oils, fragrances, flavors, sweeteners, menthol, pepperment oil, pine tar, camphor, benzoin preparations, tolu, turpentine oil and the like.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Suitably the carrier is a cyclopentasiloxane, preferably a polyalkylcyclopentasiloxxane an ethylene diglyceride, a propylene glyceride, and mixtures of said glycerides. It especially desirable that the carrier is decamethylcyclopentasiloxane, an ethylene diglyceride, a propylene diglyceride, a propylene triglyceride and mixtures of said glycerides, wherein the glyceride moieties are selected from the group consisting of caprilic and capric glycerides.
[0017] Suitably the ester is a lactate ester, desirably it is a C 12 to C 18 alkyl lactate, preferably where the alkyl group is cetyl, lauryl, isostearyl and myristyl and mixtures thereof.
[0018] Preferably, the glycol is a C 3 to C 8 glycol, including but not limited to propylene, dipropylene, hexylene, 1,3-butylene, diethylene, triethylene, tetrapropylene and tetraethylene glycols, polyethylene glycol 200 and polypropylene glycol 425 amd 2-methyl-1,3-propane diol and mixtures thereof
[0019] While the invention is not limited thereto, bio-active materials suitable for use in this invention include those selected from the group consisting of decongestants, antihistamines, analgesics such as butorphanol tartrateantitussives, anticholinergics, steroids, suitably corticosteroids such as triamcinolone acetonide antibiotics antispasmotics, such as beclamethasone dipropionate, brochodilators, such as ipratropium bromide, fluticasone pripionate, albuterol sulfate, vitamins, such as vitamine B-12 or cyanocobalamine, hormones, suitably peptide hormones such as calcitonin-salmon, antihypertensives such as propranolol, and antimicrobials.
[0020] Especially suitable for purposes of this invention as the bio-active material are decongestants. Most suitably oxymetazoline, xylometazoline, naphazoline, phenylephrine, ephedrine in water soluble form especially when in the form of a pharmacologically acceptable salt, such as a hydrochloride or sulfate.
[0021] The ranges of the components of the spray composition are suitably from about 50-about 90 wt. % of the carrier, from about 10-about 40 wt % of the water insoluble ester, from about 1 to about 5 wt. % of the water soluble glycol, and from about 0.01 to about 2 wt. % of the bio-active material, to a total wt % of 100. Preferably the ranges are from about 60 about 90 wt. % of the carrier, from about 10 about 30 wt % of the water insoluble ester, from about 1 to about 3 wt. % of the water soluble glycol and from about 0.01 to about 2 wt. % of the bio-active material.
[0022] The sprays of the present invention are administered by spraying into the nasal cavity. The actual volume sprayed may lie between about 20 and about 80 micro liters. This amount is readily set by those skilled in the art of valve design for squeeze bottles and spray bottles. Thus the dosage of bio-active delivered is determined by its concentration in the composition. The needed frequency of administration may be readily determined by those skilled in the art based on present knowledge and not requiring undue experimentation.
EXAMPLES
[0023] (All quantities are in wt. % unless otherwise noted)
Example #1 Nasal Decongestant 12 Hour Duration
[0024] [0024] 1. Oxymetazoline.HCl 0.05 2. Propylene Glycol 2.50 3. C 12 —C 15 Alkyl Lactate 20.00 4. Dimethylcyclopentasiloxane 77.45 100.00
[0025] Components # 1 and #2 are heated to 50° C. until clear and uniform then the batch is cooled the #3 is added with mixing and when clear, #4 is added and mixed. The batch may then be charged to a spray container in suitable quantities.
Example #2 Nasal Decongestant 8 Hour Duration
[0026] [0026] 1. Xylometazoline.HCl 0.10 2. Propylene Glycol 2.50 3. C 12 —C 15 Alkyl Lactate 20.00 4. Cyclopentasiloxane 77.40 100.00
[0027] This mixture is prepared in accordance with the procedures of Example #1
Example #3 Nasal Decongestant 4 Hour Duration
[0028] [0028] 1. Phenylephrine.HCl 0.50 2. Propylene Glycol 5.00 3. C 12 —C 15 Alkyl Lactate 30.00 4. Cyclopentasiloxane 64.50 100.00
[0029] This mixture is prepared in accordance with the procedures of Example #1
Example #4 Nasal Decongestant 12 Hour Duration
[0030] [0030] 1. Oxymetazoline.HCl 0.05 2. 1,3-Butylene Glycol 2.50 3. Lauryl Lactate 20.00 4. Cyclopentasiloxane 77.45 100.00
[0031] This mixture is prepared in accordance with the procedures of Example #1
Example #5 Nasal Decongestant and Antihistamine
[0032] [0032] 1. Oxymetazoline.HCl 0.05 2. Chlorpheniramine Maleate 0.20 3. Propylene Glycol 2.50 4. Myristyl Lactate 20.00 5. Cyclopentasiloxane 77.25 100.00
[0033] Components # 1, #2 and #3 are heated to 50° C. until clear and uniform then the batch is cooled the #4 is added with mixing and when clear, #5 is added and mixed. The batch may then be charged to a spray container in suitable quantities.
Example #6 Nasal Decongestant
[0034] [0034] 1. Oxymetazoline.HCl 0.05 2. Propylene Glycol 2.00 3. Isostearyl Lactate 23.00 4. Cyclopentasiloxane 74.95 100.00
[0035] This mixture is prepared in accordance with the procedures of Example #1
Example #7 Nasal Decongestant 12 Hour Duration
[0036] [0036] 1. Oxymetazoline HCl 0.05% 2. Propylene Glycol 1.50% 3. C 12 —C 15 Alkyl Lactate 20.00% 4. Caprylic/Capric Triglyceride 78.45% 100.00%
[0037] This mixture is prepared in accordance with the procedures of Example #1.
Example #8 12 Hour Duration Nasal Decongestant
[0038] [0038] 1. Oxymetazoline HCl 0.05% 2. Propylene Glycol 1.50% 3. C 12 —C 15 Alkyl Lactate 10.00% 4. Propylene Glycol Dicaprylate/Dicaprate 88.45% 100.00%
[0039] This mixture is prepared in accordance with the procedures of Example #1. | There is provided non-aqueous liquid spray compositions comprising a pharmacologically acceptable non aqueous liquid carrier in which said bioactive material is directly insoluble, a pharmacologically acceptable water insoluble ester of a water soluble acid soluble in said carrier, a pharmacologically acceptable water soluble glycol soluble in said ester and a pharmacologically acceptable water soluble bio-active material soluble in said glycol but not directly soluble in the carrier. There are also provided methods of producing and administering such compositions. | 8 |
This application is a Divisional of U.S. application Ser. No. 10/829,427, filed on Apr. 22, 2004, now U.S. Pat. No. 7,189,548.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to modified sarcosine oxidases, genes and recombinant DNAs thereof, and methods for preparing the same.
2. Background Art
Sarcosine oxidases are enzymes with a catalytic activity to hydrolyze sarcosines to produce glycine and formaldehyde, which can be used to measure the amount of creatinine in human serum or urine, or can be utilized as diagnostic agents for various diseases such as renal disease.
Sarcosine oxidases are previously known to be produced by bacterial strains such as Corynebacterium genus (see J. Biochem., 89,599 (1981)), Bacillus genus (see JP Patent Publication (Unexamined Application) No. 54-52789), Cylindrocarbons genus (see JP Patent Publication (Unexamined Application) No. 56-92790), Pseudomonas genus (see JP Patent Publication (Unexamined Application) No. 60-43379), Arthrobacters genus (see JP Patent Publication (Unexamined Application) No. 2-265478). However, in typical creatine quantitative reactions in slightly alkaline range (pH 7.5-8.0), bilirubin affects the measurement value, thus causing a difficulty upon measuring. Until now, genetically modified enzymes having optimal pH in the slightly acidic range, which are produced by modifying sarcosine oxidase genes from Bacillus genus, aiming for measuring in the slightly acidic range where effects of bilirubin are less, are also known (see JP Patent Publication (Unexamined Application) No. 2000-175685). However, these modified enzymes were not practical with respect to instability in the slightly acidic range.
As described above, when enzymatically quantifying creatinine or creatine, the reliability of the measurements are reduced if substances such as bilirubin affect them, since the amounts of the two substances in serum or blood are extremely small. It is also known that when measurements are performed in the slightly acidic range where the effects of bilirubin etc. are small, decrease in stability occurs. To solve these problems with improvements other than of enzymatic nature, the amount of sarcosine oxidase in the active formulation had to be increased than it is normally used; buffers had to be selected appropriately; or additives had to be added. However, improvements by such means could increase the cost of measurement reagents and therefore were not practical.
The object of the present invention is to provide sarcosine oxidases which have optimal pH and show high activity in the slightly acidic range, which also have improved stability.
SUMMARY OF THE INVENTION
Consequently, the inventors investigated further into the problem mentioned above, and as a result of genetically modifying sarcosine oxidase genes from Bacillus genus (shown in SEQ ID NO: 2 of JP Patent Publication (Unexamined Application) No. 5-115281) (SEQ ID NO: 2), succeeded in obtaining sarcosine oxidases with improved activity in the slightly acidic range and improved stability, thus completing the present invention.
The present invention provides the following:
(1) A modified sarcosine oxidase with improved stability in the acidic range compared to wild-type sarcosine oxidases. (2) The modified sarcosine oxidase according to item (1) having a residual activity of 90% or more after 5 hours of heat treatment at pH 6.0, 25° C., and 70% or more after 17 hours of heat treatment at pH 6.0, 25° C. (3) The modified sarcosine oxidase according to item (2) wherein an activity against sarcosine in the acidic range is improved compared to a wild-type sarcosine oxidase. (4) The modified sarcosine oxidase according to item (3) with a Km value of less than 6 mM against sarcosine at pH 6.5. (5) A modified sarcosine oxidase having the following physicochemical properties:
(a) action: hydrolyze 1 mol of sarcosine to produce 1 mol of glycine and 1 mol of formaldehyde.
(b) optimal pH: around 6.5
(c) stable pH range: between 6.0 and 11.0
(d) optimal temperature: 60° C.
(e) thermostability: around 50° C. (pH 7.5)
(f) stability at pH 6.0: residual activity of 90% or more at 25° C., pH 6.0, 5 hours; 70% or more at 25° C., 17 hours
(g) molecular weight: approximately 43,000 (SDS-PAGE)
(h) Km value: 5.9 mM against sarcosine (pH 6.5)
(6) A modified sarcosine oxidase of the following (a), (b), or (c):
(a) protein composed of the amino acid sequence represented by SEQ ID NO: 1;
(b) protein composed of an amino acid sequence wherein one or some amino acid(s) are deleted, substituted, or added from the amino acid sequence represented by SEQ ID NO: 1, and which has sarcosine oxidase activity;
(c) protein composed of an amino acid sequence which shows 80% or more homology to the amino acid sequence represented by SEQ ID NO: 1, and which has sarcosine oxidase activity.
(7) A sarcosine oxidase gene encoding a modified sarcosine oxidase of the following (a), (b), or (c):
(a) protein composed of the amino acid sequence represented by SEQ ID NO: 1;
(b) proteins composed of an amino acid sequence wherein one or some amino acid(s) are deleted, substituted, or added from the amino acid sequence represented by SEQ ID NO: 1, and which has sarcosine oxidase activity;
(c) proteins composed of an amino acid sequence which shows 80% or more homology to the amino acid sequence represented by SEQ ID NO: 1, and which has sarcosine oxidase activity.
(8) A recombinant DNA characterized in that the sarcosine oxidase gene according to item (7) is inserted into vector DNA. (9) A transformant or transductant comprising the recombinant DNA according to item (8). (10) A method for preparing a modified sarcosine oxidase characterized by culturing the transformant or transductant according to item (9) in a medium, and collecting a sarcosine oxidase from the culture.
According to the present invention, sarcosine oxidases, in particular sarcosine oxidases which show optimal pH and high activity in the slightly acidic range and have improved stability can be prepared efficiently, thus making the invention is industrially useful.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the stable pH range of the modified sarcosine oxidase of the present invention;
FIG. 2 shows the optimal pH of the modified sarcosine oxidase of the present invention;
FIG. 3 shows the optimal temperature of the modified sarcosine oxidase of the present invention;
FIG. 4 shows the thermostability of the modified sarcosine oxidase of the present invention; and
FIG. 5 shows the activity of the modified sarcosine oxidase of the present invention and of wild-type sarcosine oxidase.
This specification includes part or all of the contents as disclosed in the specifications of Japanese Patent Applications Nos. 2003-121533, 2003-396807 and 2004-116345, which are the base of the priority claim of the present application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail.
The sarcosine oxidases of the present invention can be obtained by modifying genes encoding sarcosine oxidases. Genes encoding sarcosine oxidases used for modification are not particularly limited. Specific examples of such genes include, for example, sarcosine oxidase gene from Bacillus genus (described in JP Patent Publication (Unexamined Application) No. 5-115281) (SEQ ID NO: 2).
Any known methods may be used as a means of modifying the above genes, and include, for example, a method of contacting a sarcosine oxidase expression plasmid vector (pSOM1) comprising sarcosine oxidase gene from Bacillus genus (described in JP Patent Publication (Unexamined Application) No. 5-115281) with a chemical mutagen such as hydroxylamine and nitrous acid; a method of subjecting the same to point mutation such as converting at random using PCR, or to site-directed mutagenesis which is a known technology of site-directed substitution or deletion mutation using commercially available kits; a method of selectively cleaving this recombinant plasmid DNA, then removing or adding the selected oligonucleotide, and linking the plasmid; and an oligonucleotide mutagenesis method.
Subsequently, the recombinant DNAs treated as above are purified using demineralized column such as QIAGEN (Funakoshi) to obtain various recombinant DNAs.
Using various recombinant DNAs thus obtained, E. coli K12, preferably E. coli DH5α, E. coli JM109 (TOYOBO), XL1-Blue (STEATAGENE) for example can be transformed or transduced to obtain transformants or transductants comprising recombinant DNAs carrying sarcosine oxidase genes with various mutations introduced.
Further, for example, in the case of transformants, the following non-limiting methods can be used to obtain strains producing sarcosine oxidases with the intended properties from the transformants obtained, which contain recombinant plasmid DNAs comprising various mutated sarcosine oxidase genes.
First, said transformants obtained are transferred to TY agar mediums with respect to each colony and cultivated. Agents such as ampicillin may be added at this time as necessary. After cultivation, colonies are transferred to two TY agar mediums as above using transfer membrane, cultivated for about 20 hours, to produce sarcosine oxidases. Inducers such as IPTG may be added at this time as necessary. After cultivation, colonies in each plate are covered with a filter, for example Hybond N+ (Amersham Phaimacia), and are attached to the filter. Then, filters on which colonies are transferred are placed on filter papers wetted with detergents for lysis treatment. After the lysis treatment, the filters are dried to prevent the colonies from running.
The two dried filters are subjected to the following process for screening. First, one of the filters is placed on a filter paper wetted with MES buffer pH 6.0 and left overnight. After drying the filter and soaking it in 500 mM Tris-HCl buffer (pH 7.7) containing sarcosine, peroxidase (or POD), Toos (or N-Ethyl-N-(2-hydroxy-3-sulfopropyl)-3-methylaniline, sodium salt, dihydrate) and 4-aminoantipyrine, intensity of purple coloring is observed. The other filter is soaked in the same solution (except using 100 mM MES buffer pH 6.5), and the intensity of the purple coloring is observed.
The results detected from the above two filters are collated, and colonies showing activity in both buffers are picked up. The colonies consequently obtained are cultivated, centrifuged to collect the bacteria, and homogenized by sonication to obtain culture supernatants. The residual activity after treatment at pH 6.0, and activity against sarcosine at pH 6.5 are measured for this sonicated culture supernatant, to obtain the desired mutant. In this way, the mutated sarcosine oxidases of the invention can be obtained.
Additionally, medium used for cultivating the above microorganisms comprises, for example, 1 or more nitrogen sources of yeast extract, peptone, meat extract, corn steep liquor, soy bean or wheat koji exudates, 1 or more inorganic salts of potassium dihydrogen phosphate, potassium hydrogen phosphate, magnesium sulfate, ferric chloride, ferric sulfate or manganese sulfate, and, further, suitable sugars and vitamins etc. as necessary.
In addition, it is appropriate to adjust the initial pH of the medium for example to 7 to 9. It is also preferred to carry out the cultivation for example at between 30 and 42° C., preferably around 37° C., for 6 to 24 hours, for example by submerged cultivation with aeration and agitation, shaking cultivation, or stationary cultivation. After cultivation, ordinary means for collecting enzymes can be used to collect modified sarcosine oxidases from the said cultures.
The cultured cells are separated from the cultures by methods including filtration and centrifugation, and washed. Modified sarcosine oxidases are preferably collected from these cells. The cells may be used as they are without further treatment, although collecting modified sarcosine oxidases from the cells using various methods for disrupting the cells such as sonic homogenizer, French press, and Dyna-Mill, methods for lysing the cell walls using cell wall degrading enzymes such as lysozyme, or methods for extracting enzymes from the cells using detergents such as Triton X-100 are preferred.
To isolate modified sarcosine oxidases from crude enzyme solution thus obtained, ordinary methods for purifying enzymes can be used. For example, it is preferred to use ammonium sulfate precipitation, precipitation with organic solvents, ion exchange chromatography, gel filtration chromatography, adsorption chromatography, electrophoresis, or suitable combinations thereof.
(Enzyme Activity)
Measurements of the activity of the enzymes according to the present invention were performed under the following condition. Enzyme activity capable of generating 1 micromol of urea per minute is defined as 1 unit.
(Preparation of Reagents)
The following solutions were prepared as reaction reagents.
1) 0.2 M sarcosine, 100 mM Tris-HCl, 2 mM KCl, 0.05% Triton-X100 pH 7.7 (activity measurement solution) 2) 80 U/ml POD solution 3) 0.2% phenol solution 4) 0.2% 4-aminoantipyrine solution 5) 0.3% SDS solution 6) 20 mM Tris-HCl, 1 mM KCl, 0.2% BSA pH 7.7 (enzyme diluent)
Next, each of the above solutions was mixed in the following amounts to prepare activity measurement solution.
1) 5 ml 2) 1 ml 3) 2 ml 4) 1 ml
Measurements were carried out as follows:
1) 0.95 ml of the activity measurement solution is preincubated at 37° C. for 5 minutes. 2) 0.05 ml of enzyme solution (adjusted to between 0.04 U/ml and 0.16 U/ml with the enzyme diluent) is added and mixed. 3) reaction is carried out at 37° C. for 10 minutes. 4) after the 10-minute reaction, the 0.3% SDS solution as above is mixed in. 5) after leaving to stand at 25° C. for 10 minutes, absorbance at 495 nm is measured.
(ODsample)
Blanks are measured by mixing in 0.3% SDS solution before adding the enzyme solution. (ODblank)
(Activity Conversion Formula)
U/ml=(ODsample−ODblank)×0.95
The present invention will now further be specifically described by means of Examples.
EXAMPLE 1
E. coli JM109 (pSOM1) containing recombinant plasmid DNA (pSOM1) (FERM BP-3604) was cultivated in LB medium (DIFCO). After collecting the bacterial cells, recombinant plasmid pSOM1 were extracted and purified from these cells using QIAGEN (QIAGEN). Approximately 100 μg of plasmid were obtained.
Using the plasmid obtained, error-prone PCR was performed with N-terminal and C-terminal primers (SEQ ID NOs: 3 and 4). In particular, Ex-taq (TAKARA SHUZO) was used with these primers under 0.075 mM manganese concentration, to carry out PCR amplification of pSOM1.
After the completion of the reaction, amplified fragments of sarcosine oxidase genes with various mutations introduced were treated with restriction enzymes Bam HI and Spe I, followed by being ligated into the vector fragment (the longer fragment) of Bam HI- and Spe I-digests of unmutated pSOM1 using T4 ligase (Boehringer).
After the ligation was complete, the reaction solution was transformed with competent Hi E. coli JM109 (TOYOBO) to prepare mutant library.
Subsequently, the mutant library was transferred to TY agar medium plates containing 50 μg/ml of ampicillin, and cultivated one day and night at 37° C. After cultivation, replicas were made on two TY agar medium plates (containing 50 μg/ml of ampicillin and 1 mM IPTG) using sterilized transfer membrane, then cultivated at 37° C. for one day and night.
Following the completion of the cultivation, the plated were cooled to 4° C. for 20 minutes, and covered with Hybond N+ (Amersham Pharmacia), and the colonies were transferred to filters. The filters on which the colonies were transferred were placed on a filter paper wetted with BugBuster (TAKARA SHUZO) to lyse the bacteria. The lysed filter was dried in a thermostat at 37° C.
One of the dried filters was placed on a filter paper wetted with 100 mM MES buffer pH 6.0 and left at 25° C. overnight. After this procedure, the filter was dried, and then coloring reaction was carried out using a solution of 100 mM sarcosine (TOKYO KASEI KOGYO), 500 mM Tris-HCl (WAKO PURE CHEMICAL INDUSTRIES), pH 7.7, 0.2 mM Toos (DOJINDO LABORATORIES), 0.16 mM 4-aminoantipyrine (TOKYO KASEI KOGYO), and 10 U/ml of POD (KIKKOMAN). Strains which showed more intense color on the filter compared to control strains were selected as candidate strains producing enzymes with excellent stability under acidic conditions.
The other filter was subjected to coloring reaction on a filter paper wetted with a solution of 0.12 mM sarcosine (TOKYO KASEI KOGYO), 100 mM MES (DOJINDO LABORATORIES), 0.2 mM Toos (DOJINDO LABORATORIES), 10 U/ml of POD (KIKKOMAN), and 0.16 mM 4-aminoantipyrine (TOKYO KASEI KOGYO) (pH 6.5). The strains which were the first to show an increase in color were selected as candidate strains producing enzymes with excellent activity under acidic conditions. From the above process, strains with excellent stability and excellent activity under acidic conditions were selected.
The selected strains were cultivated in 2 ml of TY medium containing 50 μg/ml of ampicillin and 1 mM IPTG. After 18 to 24 hours of cultivation, bacterial cells were collected by centrifugation, the medium was substituted with a solution of 20 mM Tris-HCl (pH 8.0), 1 mM KCl, pH 7.7, homogenized by sonication, and centrifuged (12000 r.p.m., 3 minutes). The activity of the supernatant obtained from the homogenization was measured under conditions of pH 7.7 and pH 6.5, and the mutants which showed a value at pH 6.5 close to the value at pH 7.7 were selected.
Next, using the homogenization supernatant of the strain with high activity at pH 6.5, stability in the slightly acidic range was evaluated. To 0.9 ml of a solution of 100 mM MES, pH 6.0, 0.1 ml of homogenate was added, and treated for 15 hours at 25° C. When the treatment was completed, 0.1 ml of the treated solution was diluted 10-fold with 0.9 ml of a solution of 200 mM Tris-HCl (pH 7.7), 1 mM KCl, and 0.2% BSA, and the activity was measured.
Mutated enzymes with improved activity and stability at pH 6.5 were prepared from the above process. Plasmids carrying the modified sarcosine oxidase genes of the above mutant was named pSOM3. The plasmid pSOM3 was deposited at the International Patent Organism Depository department at National Institute of Advanced Industrial Science and Technology as FERM BP-8370.
By determining the base sequence of sarcosine oxidases encoded by the present plasmids using CEQ 2000 DNA Sequencing System (Beckman Coulter), the sarcosine oxidases of the present invention were found to be substituted as follows: glutamate residue at amino acid 61 to lysine residue, aspartate residue at amino acid 241 to glycine residue, and glutamate residue at amino acid 324 to histidine residue (shown in SEQ ID NO: 1).
EXAMPLE 2
E. coli JM109(pSOM3) comprising the modified sarcosine oxidase genes obtained as above was cultivated with shaking in 100 ml of TY medium (1% bacto-tryptone, 0.5% bacto-yeast extract, 0.5% NaCl, pH 7.5) containing 50 μg/ml ampicillin for 16 hours, after which 10 ml was inoculated to 1 L of TY medium prepared similarly (except for containing 1 mM IPTG). After inoculation, it was cultivated at 120 r.p.m., 37° C. for approximately 20 hours.
Step 1 (Crude Enzyme Solution)
After the completion of cultivation, bacterial cells were collected by centrifugating 1 L of culture, and the cells were suspended in 50 ml of a solution of 20 mM Tris-HCl, 50 mM EDTA, pH 8.0. The cell suspension thus obtained was homogenized by sonication to obtain crude enzyme solution.
Step 2 (Ammonium Sulfate Precipitation)
Ammonium sulfate precipitation was performed by adding 20% ammonium sulfate to 50 ml of the crude enzyme solution obtained as above. Following ammonium sulfate precipitation, the precipitate was dissolved in a buffer of 50 mM KCl, 20 mM Tris-HCl and 2 mM EDTA.
Step 3 (DEAE-TOYOPEARL Ion Exchange Chromatography)
The above crude enzyme solution was adsorbed to a column packed with 300 ml of DEAE-TOYOPEARL (TOSO), washed with 600 ml of a solution of 100 mM KCl, 20 mM Tris-HCl, 2 mM EDTA, pH 8.0, then eluted with a solution of 150 mM KCl, 20 mM Tris-HCl, 2 mM EDTA, pH 8.0. When the elution was completed, the high purity fraction was collected, concentrated, and then dialyzed against 50 mM phosphate buffer pH 7.5 containing 150 mM KCl and 2 mM EDTA.
Step 4 (Sephadex G-75 Gel Filtration)
To a column packed with 200 ml of Sephadex G-75 (Pharmacia) bufferized with 50 mM phosphate buffer pH 7.5 containing 150 mM KCl and 2 mM EDTA, 15 ml of the enzyme solution from step 3 was charged to perform gel filtration. The activity of the purified enzyme obtained per OD 280 nm was approximately 25 U. The physicochemical properties of the sarcosine oxidase obtained were as follows.
EXAMPLE 3
pH Stability
After treating the present enzyme for 5 hours each at 25° C. in each of the following buffers, the residual activities were measured. The results were as shown in FIG. 1 . From FIG. 1 , it can be seen that the stable pH range was between pH 6.0 and 11.0.
50 mM MES-NaOH (pH 5.5, 6.0, 6.5)
50 mM calcium phosphate buffer (pH 6.5, 7.0, 7.5, 8.0)
50 mM Tris-HCl buffer (pH 8.0, 8.5, 9.0)
50 mM CHES-NaOH buffer (pH 9.0, 9.5, 10.0)
50 mM CAPS-NaOH (pH 10.0, 10.5, 11.0)
Optimal pH
When the enzyme reactions were carried out in the presence of 100 mM sarcosine, 0.2 mM Toos, 0.16 mM 4-aminoantipyrine and 10 U/ml peroxidase in each of the following buffers, the results were as shown in FIG. 2 . From FIG. 2 , it can be seen that the optimal pH was around 6.5.
50 mM MES-NaOH (pH 5.5, 6.0, 6.5)
50 mM potassium phosphate buffer (pH 6.5, 7.0, 7.5, 8.0)
50 mM Tris-HCl buffer (pH 8.0, 8.5, 9.0)
50 mM CHES-NaOH buffer (pH 9.0, 9.5, 10.0)
Optimal Temperature
When the enzyme reactions with 100 mM sarcosine were carried out in the presence of 100 mM Tris-HCl (pH 7.7) at different temperatures, the results were as shown in FIG. 3 . From FIG. 3 , it can be seen that the optimal temperature was around 60° C.
Thermostability
Heat treatments at different temperatures for 10 minutes using 50 mM potassium phosphate buffer (pH 7.5) were carried out to evaluate thermostability. The results on thermostability were as shown in FIG. 4 . The present enzyme was stable up to around 50° C.
Km Value
Km values at different pH values calculated from Lineweaver-Burk calculation method were as follows. In addition, the reaction was carried out using 50 mM MES buffer (for pH 6.5 and 7.0) or Tris-HCl buffer (for pH 7.7), and using a solution of 0.2 mM Toos, 0.16 mM 4-aminoantipyrine, and 10 U/ml peroxidase as coloring agents.
As a result, the Km values at different pH were 5.9 mM (pH 6.5), 3.8 mM (pH 7.0), and 3.9 mM (pH 7.7).
EXAMPLE 4
Wild-type and modified sarcosine oxidase 1.2 U/ml each were subjected to reaction with 5 μM of sarcosine at 37° C., pH 6.5. The composition of the reaction solution was 50 mM MES, 60 mM NaCl, 0.2 mM Toos, 0.16 mM 4-aminoantipyrine, and 20 U/ml peroxidase. The results are shown in FIG. 5 . As can be seen from FIG. 5 , modified sarcosine oxidase exhibited significantly good activity at pH 6.5 compared to the wild-type.
EXAMPLE 5
Wild-type and modified sarcosine oxidase were left for 17 hours in 100 mM MES (pH 6.0) at 25° C. The residual activity after the treatment was 13.6% for the wild-type, and 72.8% for the modified enzyme.
All the publications, patents and patent applications cited herein are incorporated herein by reference in their entirely. | An isolated DNA molecule encoding modified sarcosine oxidases having optimal pH, high activity in the slightly acidic range and improved stability and a method for preparing the modified sarcosine oxidases is disclosed. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to operation of x-ray fluoroscope devices during surgery and more particularly, to a head-activated fluoroscopic control which includes a transmitter for transmitting partially collimated, continuous wave electro-magnetic radiation such as infrared radiation, and a receiver for receiving the electromagnetic radiation. The transmitter is located in a small cartridge adapted for mounting on the eyeglasses, headband or alternative headpiece of a surgeon or assisting physician and the receiver includes an electromagnetic detection circuit combined with a phase-lock type frequency detector which is tuned to the frequency of the electromagnetic radiation emitted by the transmitter. The receiver may be either located in close proximity to a fluoroscope monitor, or built into the monitor, while the fluoroscope is typically characterized by a C-arm unit having an x-ray tube and beam collimator positioned above the operating table and an image intensification unit located beneath the operating table to facilitate operation of the fluoroscope responsive to turning of the surgeon or attending physician's head toward the fluoroscope monitor and transmission of the electromagnetic radiation in a partially collimated beam from the transmitter to the receiver.
The use of fluoroscopic radiation is widespread in many surgical procedures, as well as diagnostic testing performed in medical centers around the world. Activation of the fluoroscopic x-ray energy is traditionally initiated by a surgeon or attending physician using a foot-operated switch. Because the foot-operated switch is located on the floor beneath the operating table where it cannot be easily viewed by the surgical team, it may be accidentally activated by one or more members of the team during the surgical procedure. Furthermore conductive body fluids may be spilled on the foot switch during the procedure, thereby causing it to malfunction. Moreover, it may be difficult for some physicians to operate the foot switch due to personal handicaps and the foot switch may be easily accidentally activated for an excessive period of time due to distractions in the operating room. The activation of fluoroscopic x-ray energy due to any one of the above circumstances results in useless, unnecessary and sometimes dangerous ionizing exposure to the patient. From observations of fluoroscopic procedures, it has been observed that up to 10% of the fluoroscopic x-ray time used during an average surgical procedure is non-productive. In practice, any needless x-ray exposure to patients or hospital workers should be avoided since the ionizing effect of x-rays to the body are cumulative. Accordingly the head-activated fluoroscopic control of this invention facilitates a highly satisfactory technique for using fluoroscopic radiation on demand in an optimum manner by the surgeon or attending physician without needless x-ray exposure to the patient and without the necessity of using the hands or feet of the surgeon or attending physician.
Upon analyzing the problem of more efficient use of fluoroscopic radiation in surgical procedures, it was noted that the physicians or surgeons do not need fluoroscopic x-ray until their eyes are focused on the fluoroscopic x-ray monitor. A continuous wave, compact infrared source cartridge was devised which is sufficiently small and light to be clipped or otherwise attached to eyeglasses, a headband or an alternative headpiece. A highly sensitive infrared detection circuit, combined with a phase-lock type frequency detector tuned to the frequency of the transmitter, was also developed as a receiver to detect the partially collimated infrared beam emitted by the transmitter cartridge. Using a combination of source beam and detector collimation and by adjusting the overall system sensitivity, an optimum triggering zone was created which allows accurate activation of the fluoroscopic x-ray, thus minimizing the unintentional fluoroscopic radiation which a patient often receives during surgery. The device also eliminates the necessity for using an awkward foot switch located on the floor beneath the operating table. The receiver is mounted on or in close proximity to the fluoroscopic x-ray monitor, which faces the area where the assisting or attending physician or surgeon normally stands during an operating room procedure and the relay contacts of the receiver are attached in parallel to the normal fluoroscopic x-ray foot switch contacts. During a typical fluoroscopic x-ray procedure, whenever the physician turns his head toward the monitor, a partially collimated, cone-shaped transmitter beam continuously emitted from the transmitter cartridge strikes the receiver and the fluoroscopic x-ray device is activated as if the conventional foot switch had been pressed. The beam collimation adjustment in the transmitter is such that the physician's line of sight must be directly at the fluoroscopic x-ray monitor to activate the receiver and energize the fluoroscope device. Conversely, when the physician turns his head away from the monitor the beam no longer strikes the receiver and operation of the fluoroscope device is terminated.
2. Description of the Prior Art
Various types of remote control switching systems are known in the art. An electro-optical switching system is detailed in U.S. Pat. No. 4,091,273, dated May 23, 1978, to William D. Fuller, et al. The system includes multiple visually activated switches, one for each one of a plurality of different electronic apparatus, each including electromagnetic radiation sensors having a detection surface and each controlling the application of electrical powe to the respective equipment in response to an impinging electromagnetic beam incident at the detection surface for a determined time interval. A pulsed electromagnetic beam is provided by a transmitter included within an electrical magnetic activating source which is held or disposed on a portion of the anatomy of the human operator who aligns the beam with the detection surface on the selected one of the switches with the aid of a visual reticle image provided by a reticle generator included in the activating source and boresighted with the transmitter. The system further includes control unit responsive to each of the radiation sensors for discriminating between the pulsed electromagnetic beam energy and the ambient energy background and for providing actuating signals to the respective equipment in response to the presence of incident pulsed electromagnetic energy at the associated visually activated switch detection surface for a determined time interval in the absence of incident pulsed electromagnetic energy at each of the other switches within the same time interval, the control unit providing actuation of the various selected equipment sequentially, one at a time. A "Remote Control Device for Operation by Radiation" is detailed in U.S. Pat. No. 4,156,134, dated May 22, 1979, to Willy Minner. The device operates by means of radiation and includes a receiver for the radiation and means for transforming the radiation into an electric signal, as well as rectification means for rectifying an electric signal. U.S. Pat. No. 4,377,006, dated Mar. 15, 1983, to Johnny Collins, et al, details an "IR Remote Control System". The remote control system is designed for a television receiver and includes a transmitter and a receiver, the transmitter being adapted for transmitting a multibit code identifying a selected function of the television receiver, wherein the data bits forming the multibit code each include a single pulse representing a first logic state and a grouping of at least two relatively close spaced pulses representing second logic state. The remote control receiver includes a self-locking detector for converting the transmitted pulses to a binary logic signal and decoding apparatus responsive to the logic signal for operating the selected television receiver function. U.S. Pat. No. 3,475,092, dated Oct. 28, 1969, to D. M. Harvey, details a "Wireless Remote Control Slide Changer". The device is designed for selectively actuating forward and reverse changing mechanism of a projector such as slide projector. The system includes a hand-held control unit which develops a pulse length modulated beam of actinic radiation for energizing photosensitive receiver mounted on the slide projector. The beam of light is chopped by using an alternatively opaque and transparent rotating or vibrating grate. An elevator remote-control apparatus is detailed in U.S. Pat. No. 4,673,911, dated June 16, 1987, to K. Yoshida. The remote control apparatus is designed such that when a desired call has been registered with the "up" button or "down" button of a remote controller an acceptance signal is delivered from an elevator control device to turn the "up" button or "down" button of the hall button device on. At the same time, a response signal corresponding to the acceptance signal is sent from the transmitter of the hall button device to the remote controller and it is received by the receiver of the remote controller, to activate the response lamp in correspondence with the call registration. Accordingly, the ascent or descent registration of an elevator can be reliably acknowledged on the remote controller side.
It is an object of this invention to provide a head-activated fluoroscopic x-ray control system which eliminates the requirement of a conventional foot switch in operating a fluoroscopic x-ray and monitor.
Another object of the invention is to provide a head-activated fluoroscopic control which is characterized by a partially collimated beam source for transmitting continuous wave electromagnetic radiation and a receiver device to detect the radiation beam and actuate set of relay contacts to selectively operate a fluoroscopic x-ray and monitor.
Yet another object of this invention is to provide head actuated control system for operating a fluoroscope during operating room procedures, which system includes a head-mounted transmitter cartridge capable of emitting a continuous cone-shaped beam of infrared radiation and a infrared receiver mounted in or located in close proximity to a fluoroscope monitor for receiving the beam and activating the fluoroscope.
Still another object of the invention is to provide a head activated control system for a fluoroscope, and a C-arm fluoroscope in particular, which control system includes an infrared emitter cartridge capable of emitting a continuous, partially collimated, cone-shaped beam of infrared radiation and a receiver built into or resting on the fluoroscope monitor, which receiver is provided with an infrared detection circuit for receiving the infrared radiation and triggering operation of the fluoroscope responsive to moving the head and viewing the monitor.
A still further object of this invention is to provide an infrared transmitter adapted for mounting on the eyeglasses, headband or alternative headpiece of a surgeon or attending physician, for emitting a continuous partially collimated infrared beam and an infrared receiver positioned in close proximity to a fluoroscopic x-ray monitor for receiving the collimated infrared beam and activating a fluoroscopic x-ray device located over an operating table.
Another object of the invention is to provide a head-activated fluoroscopic control which includes a cartridge transmitter capable of transmitting a continuous wave source of partially collimated infrared radiation and provided with a light weight cable, which transmitter can be adapted to mount on a headband, goggles, eyeglasses or an alternative headpiece and further including a highly sensitive infrared detector mounted on, in or near a fluoroscopic x-ray monitor, wherein the collimated beam emitted by the transmitter is received by the receiver responsive to turning of the surgeon's or physician's head toward the monitor, in order to activate the fluoroscopic x-ray and monitor.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved head-activated fluoroscopic control which is characterized by an infrared transmitter capable of emitting a continuous, partially collimated, cone-shaped wave source of infrared radiation for a selected distance, a sensitive infrared detector located on or mounted in a fluoroscopic x-ray monitor facing the operating area, wherein the receiver receives the carefully collimated beam of infrared radiation and activates the fluoroscopic x-ray and monitor responsive to turning of the physician's or surgeon's head toward the monitor.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a physician, an operating table and a patient lying on the operating table, along with transmitter and receiver elements of a preferred embodiment of the head-activated fluoroscopic control of this invention;
FIG. 2 is a side view of the physician, operating table, patient and head actuated fluoroscope control elements illustrated in FIG. 1;
FIG. 3 is a front view of a typical infrared receiver for placement on the fluoroscope monitor of a fluoroscopic x-ray device;
FIG. 4 is a front view of the infrared receiver mounted on the fluoroscope monitor, more particularly illustrating cones of infrared radiation superimposed thereon;
FIG. 5 is a perspective view of a typical infrared emitter cartridge mounted on the headband worn by a physician;
FIG. 6 is a perspective view of the infrared emitter cartridge clipped on a physicians cap;
FIG. 7 is a perspective view of the infrared emitter mounted on a head clip;
FIG. 8 is a schematic diagram of a typical transmitter circuit; and
FIG. 9 is a schematic diagram of a typical receiver circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3 of the drawings, the head activated fluoroscopic control of this invention includes an infrared source or transmitter 1, mounted on the earpiece of eyeglasses 21, worn by the physician, and an infrared receiver 10, resting on a fluoroscope monitor 29. A C-arm fluoroscope 28 includes an x-ray tube and beam collimator 33, complete with control wiring 37, mounted on a mount bracket 36 and positioned directly over a patient reclining on an operating table 38. The mount bracket 36 is mounted in adjustable, sliding relationship on a curved C-arm 35, which extends from the mount bracket 36 to an image intensification unit 34, located beneath the operating table 39. The fluoroscope 28 is designed to selectively x-ray the patient by operation of the head-activated fluoroscopic control of this invention, and display the x-ray picture on the fluoroscope monitor 29, as hereinafter further described. As further illustrated in FIG. 1, the fluoroscope monitor 29 includes a monitor cabinet 30, having a round cabinet screen 31, for viewing by the attending physician. The infrared receiver 10 is further characterized by a receiver housing 11, having a sensor window 12 for receiving the cone-shaped infrared radiation beam 9, emitted from an emitter cartridge 2, provided with cartridge wiring 3a, which emitter cartridge 2 characterizes the infrared transmitter 1. Accordingly, when the infrared radiation beam 9 strikes the sensor window 12 of the infrared receiver 10 as the physician's head turns toward the fluoroscope monitor 29, the fluoroscope 28 is activated to x-ray the patient 38 and the x-ray picture is displayed on the cabinet screen 31 of the fluoroscope monitor 29. As illustrated in FIG. 3, in a first preferred embodiment of the invention the receiver housing 11 includes the sensor window 12, a test light 3a and a 3-position switch 11a. The three-position switch 11a is placed in the "on" position to arm the infrared receiver 10 and may be manipulated into the "test" position to test the head operated fluoroscopic control without activating the fluoroscope 28. The unit is rendered inoperative by placing the 3-position switch in the middle, or "off" position.
Referring now to FIGS. 5-7 of the drawings, in alternative preferred embodiments of the invention the emitter cartridge 2 of the infrared transmitter 1 can be removably attached by means of a cartridge clip 2a to the headband 22 (FIG. 5) or the head cover 27 (FIG. 6), under circumstances where the physician does not wear eyeglasses. Furthermore, referring to FIG. 7, in another alternative preferred embodiment of the invention the emitter cartridge 2 can be inserted into one of several band clamps 41, spaced on the cartridge band 40, for the same purpose.
Referring now to FIGS. 1, 2, 8 and 9 of the drawings, a typical control cabinet 32 and cooperating circuits for operating the fluoroscope 28, as well as the infrared transmitter 1 and infrared receiver 10 are illustrated. The transmitter circuit 4 illustrated in FIG. 8 includes an oscillator 5, electrically connected to a driver 6, which drives an infrared light-emitting diode 7, to produce infrared radiation 8. Similarly, the receiver circuit 20 illustrated in FIG. 9 includes a sensor 13, which receives and senses the infrared radiation 8, a pre-amplifier 14, electrically connected to the sensor 13, a filter 15 electrically connected to the pre-amplifier 14 and a decoder 16 electrically connected to the filter 15 and to a relay 17. The relay 17 energizes the fluoroscopic x-ray function in the fluoro circuit 18, located in the control cabinet 32 of the fluoroscope 28. The fluoro circuit 18 may also be provided with a foot switch 26 for alternatively manually activating the fluoroscopic x-ray function in conventional fashion.
Accordingly, referring again to the drawings, it will be appreciated that the attending physician is free to conduct the planned operating room procedure on the patient without concern as to the location of a conventional foot pedal or other switch device placed on the operating room floor in close proximity to the operating table 38. As illustrated in FIGS. 1 and 4, when it is desired to operate the fluoroscope 28, the physician merely turns his head to face the cabinet screen 31 of the fluoroscope monitor 29 and the infrared radiation beam 9, which is continuously emitted in a controlled collimated cone from the emitter cartridge 2 of the infrared transmitter 1, strikes the sensor window 12 of the infrared receiver 10 in a beam print 9a, illustrated in phantom in FIG. 4. The infrared radiation beam 9 thus activates the sensor 13, pre-amplifier 14, filter 15, decoder 16 and relay 17 of the receiver circuit 20, illustrated in FIG. 9 and operation of the relay 17 causes the fluoroscope 28 to emit x-rays. The results of these x-rays are displayed on the cabinet screen 31 of the fluoroscope monitor 29. Operation of the fluoroscope 28 is immediately terminated when the physician move his head such that he is no longer facing the fluoroscope monitor 29, thus moving the beam print 9a from contact with the sensor window 12 and interrupting contact between the infrared radiation beam 9 and the housing window 12.
Since the infrared transmitter 1 is capable of emitting a continuous, carefully collimated wave source of infrared radiation represented by the infrared radiation beam 9 whether the physician is looking toward the fluoroscope monitor 29 or not, the infrared receiver 10 is almost immediately activated when the physician turns his head to view the fluoroscope monitor 29. However, a slight delay is built into the receiver circuit 20 to facilitate inadvertent turning of the physician's head and scanning the infrared radiation beam 9 across the sensor window 12 without activating the fluoroscope 28. The infrared radiation beam 9 is collimated to an optimum beam angle which yields a beam print 9a of desired area, as illustrated in FIG. 4, which area was determined by trial and error in various fluoroscopic x-ray experiments. Furthermore, the infrared receiver 10 is a highly sensitive infrared detector provided with pre-amplification and filtering functions to operate in all except rapid scanning circumstances of incidence of the infrared radiation beam 9 with the sensor window 12, as further illustrated in FIG. 4. The infrared receiver 10 also operates to reject extraneous pulses which may eminate from other remote control devices, such as video cassette recorders, television sets and the like, as well as ambient noise. A frequency discriminator, (not illustrated) when locked onto the continuous wave source, closes the relay 17, the contacts of which are located in parallel with the fluoro circuit 18. This wiring arrangement does not preclude the use of the foot switch 26, illustrated in FIG. 9, should the head-activated fluoroscopic control device fail for any reason.
It will be appreciated by those skilled in the art that the head-activated fluoroscopic control of this invention allows the physician to concentrate on his work rather than where the foot switch 26 is located at any given time during the operating room procedure. The device can be retrofitted on any existing x-ray machine having fluoroscopic x-ray capability, or the infrared receiver 10 may be built into the fluoroscope monitor 29 component of the device, as illustrated in FIG. 4.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A head-activated fluoroscopic control which is characterized in a preferred embodiment by a continuous wave infrared transmitter located in a cartridge adapted for attachment to eyeglasses, a headband or other headpiece worn by a surgeon or attending physician and a detector or receiver tuned to the frequency of the continuous wave infrared transmitter for receiving a partially collimated infrared signal beam and activating a fluoroscope. The infrared transmitter emits the collimated beam and the beam is received by the receiver when the surgeon's head is turned toward the fluoroscope monitor upon which the receiver rests or in which the receiver is mounted, to facilitate selective operation of the fluoroscope during surgery. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to sources of single photons, and particularly to tunable, compact single-photon sources and quantum key distribution (QKD) systems using same.
BACKGROUND OF THE INVENTION
QKD involves establishing a key between a sender (“Alice”) and a receiver (“Bob”) by using either single-photons or weak (e.g., 0.1 photon on average) optical signals (pulses) called “qubits” or “quantum signals” transmitted over a “quantum channel.” Unlike classical cryptography whose security depends on computational impracticality, the security of quantum cryptography is based on the quantum mechanical principle that any measurement of a quantum system in an unknown state will modify its state. As a consequence, an eavesdropper (“Eve”) that attempts to intercept or otherwise measure the exchanged qubits introduced errors that reveal her presence.
The general principles of quantum cryptography were first set forth by Bennett and Brassard in their article “Quantum Cryptography: Public key distribution and coin tossing,” Proceedings of the International Conference on Computers, Systems and Signal Processing, Bangalore, India, 1984, pp. 175-179 (IEEE, New York, 1984). Specific QKD systems are described in U.S. Pat. No. 5,307,410 to Bennett (“the Bennett Patent”), which patent is incorporated by reference herein, and in the article by C. H. Bennett entitled “Quantum Cryptography Using Any Two Non-Orthogonal States”, Phys. Rev. Lett. 68 3121 (1992), which article is incorporated herein by reference. The general process for performing QKD is described in the book by Bouwmeester et al., “The Physics of Quantum Information,” Springer-Verlag 2001, in Section 2.3, pages 27-33.
Entanglement-based Quantum Communication (QC) and, in particular, QKD, is one of the most promising applications of Quantum Information Science (QIS). A number of technical challenges, however, must be overcome before QKD becomes commercially practical. One of these challenges includes developing high-photon-flux entanglement sources for telecommunication wavelengths (e.g., 1550 nm). Because of the low attenuation of 1550-nm photons in optical fibers, they are natural information carriers for long-distance communication links.
Because quantum communication is based on single photon exchange and detection, it is very important to minimize the number of “unintended” photons—that is to say, the photons that do not participate in the information exchange. Therefore, deploying QKD system in an existing optical fiber communication infrastructure populated by classical communication channels requires very aggressive spectral filtering to minimize the background noise and optimize the signal-to-noise ratio (SNR) at the receiver.
For optimal quantum communication system performance, the width and the shape of the receiver bandpass filter must match the transmitted signal. Narrowing the transmitter spectrum decreases the receiver spectral bandwidth. Since the received noise is proportional to receiver spectral bandwidth, using narrow-line transmitters results in higher SNR, which extends the quantum channel distance budget.
Spontaneous parametric processes naturally produce relatively broadband emission spectra, typically on the order of a few nm to few tens of nm. A broad signal spectrum can cause the signals to spread due to dispersion in fiber-optics-based QKD system. Hence, additional filtering is required. One way to perform such filtering is to use an external bandpass filter at the transmitter output. Unfortunately, this decreases the photon flux and overall link efficiency, which reduces the performance of the quantum communication system.
SUMMARY OF THE INVENTION
One aspect of the invention is a robust, quickly tunable narrow-linewidth entangled photon source system based on Spontaneous Parametric Down Conversion (SPDC) of the pump light in periodically polled LiNbO3 (PPLN) waveguides. In an example embodiment, the photon source system is operated in a synchronous (i.e.—pulsed) regime at the telecom C-Band wavelength (1529 to 1563 nm). In order to tailor the output spectrum, the PPLN waveguide is arranged between two end waveguides having LiNbO3-embedded Bragg gratings, thereby forming a tunable Fabry-Perot cavity. The resulting narrow output linewidth of the entangled photons makes the system desirable for use in a long-distance Quantum Key Distribution (QKD) system. The system is also desirable for use in entanglement-based QKD systems in hybrid optical networks where quantum channels are wavelength-multiplexed with classical (i.e., non-single-photon) channels. By varying the applied electric field in the end waveguides, the spectrum of single/entangled photons can be rapidly tuned, making the system appropriate for use in QKD systems and reconfigurable QKD networks.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description present embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the photon source system of the present invention;
FIG. 2 is a plot of the reflected light intensity (arbitrary units) vs. wavelength (nm) for the Fabry-Perot cavity formed by the three waveguides of the photon source system of FIG. 1 ;
FIG. 3 is a plot of the wavelength (λ) vs. the applied electric field (V/cm) for the electrodes in the end waveguides, illustrating the shift in cavity resonant wavelength by changing the media refractive index via an electro-optic effect; and
FIG. 4 is a schematic diagram of a QKD system that utilizes the photon source system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention includes a tunable narrow-linewidth entangled photon source system (hereinafter, simply “photon source system” or “system”) based on Spontaneous Parametric Down Conversion (SPDC) of the pump light in periodically polled lithium niobate (or LiNbO 3 ) (PPLN) waveguides. FIG. 1 is a schematic diagram of an example embodiment of a photon source system 10 in the form of a composite waveguide. Photon source 10 includes an entanglement-generating PPLN waveguide 20 that includes a guiding layer 22 having formed therein a Bragg grating 24 . Waveguide 20 has opposite ends 26 A and 26 B.
It is noted here that that in recent years, PPLN waveguides have become commercially available at reasonable prices from a number of vendors (e.g., HC Photonics, Inc., and Thorlabs, Inc.).
System 10 also includes two end waveguides 30 A and 30 B in the form of tunable Bragg filters/reflectors arranged at respective ends 26 A and 26 B of waveguide 20 , so that waveguide 20 is sandwiched therebetween. Waveguides 30 A and 30 B each include respective waveguide layers 32 A and 32 B and respective Bragg gratings 34 A and 34 B formed therein. Waveguides 30 A and 30 B each also includes electrode pairs 50 A, 52 A and 50 B, 52 B arranged on respective sides of waveguide layers 32 A and 32 B so that the waveguide layers can be subjected to an electric field, as explained below. For the end waveguides 30 A and 30 B, suitable waveguides are LiNbO3-embedded tunable Bragg gratings such as those recently been developed by SWET Optics, GmbH of Germany. Waveguide 20 , in combination with the surrounding end waveguides 30 A and 30 B, form a Fabry-Perot cavity having an adjustable cavity resonant wavelength.
Electrodes 50 A and 52 A are electrically coupled to a voltage source 60 A, while electrodes 50 B and 52 B are electrically coupled to a voltage source 60 B.
In an example embodiment, system 10 also includes a temperature control element 70 in thermal communication with waveguide 20 to control the temperature of the waveguide. A temperature sensor 78 is also provided to measure the temperature of waveguide 20 and provide a temperature signals ST.
System 10 also includes a pump light source 90 adapted to emit pump light 92 , e.g., at a wavelength of 775 nm.
System 10 further includes a controller 100 electrically coupled to pump light source 90 , voltage sources 60 A and 60 B, temperature control element 70 , and temperature sensor 78 . In an example embodiment, controller 100 is a microprocessor, or a computer that includes a microprocessor, wherein the controller is programmed with instructions to carry out the method of operation of the system as described below. In an example embodiment, the microprocessor is or includes a field-programmable gate array (FPGA). The instructions in controller 100 can be implemented either in hardware or software (e.g., an FPGA or central processing unit (CPU)), and can exist in a variety of forms both active and inactive. For example, they can exist as one or more software programs comprised of program instructions in source code, object code, executable code or other formats. Any of the above formats can be embodied on a computer-readable medium, which include storage devices and signals, in compressed or uncompressed form. Exemplary computer-readable storage devices include conventional computer system RAM (random access memory), ROM (read only memory), EPROM (erasable, programmable ROM), EEPROM (electrically erasable, programmable ROM), flash memory and magnetic, optical disks or tapes.
Method of Operation
With continuing reference to FIG. 1 , in the operation of photon source system 10 , controller 100 sends a pump signal SP to pump light source 90 , which in response thereto generates pump light 92 at a desired wavelength. In an example embodiment, pump light source 90 —and thus photon source system 100 —operates in synchronous (i.e.—pulsed) regime, preferably at an output wavelength in the telecommunication C-Band, namely, between 1529 nm and 1563 nm.
In an example embodiment, the wavelength of pump light 92 is 775 nm. In a more general example embodiment, the pump light has a wavelength that is half that of one of a desired telecommunication wavelengths, such as those mentioned above. Pump light 92 serves to generate entangled photons P 1 and P 2 (dashed arrows) within guiding layer 22 of waveguide 20 via a SPDC process. Photons P 1 and P 2 are outputted from end waveguide 30 B as output light (output photons) 102 .
Controller 100 also receives temperature signal ST from temperature sensor 78 and in response thereto controls the temperature of waveguide 20 via temperature control element 70 and a temperature control signal STC provided thereto.
Meanwhile, controller 100 sends voltage control signals SA and SB to voltage controllers 60 A and 60 B. In response thereto, voltage controllers 60 A and 60 B provide voltage signals SVA and SVB (not shown) to their corresponding electrodes 50 A, 52 A and 50 B, 52 B so as to create first and second electrical potentials between the two sets of electrodes, which in turn generates respective electric fields within waveguide layers 32 A and 32 B. The electrical fields serve to change the media index of refraction and shift the cavity resonant wavelength of the Fabry-Perot cavity formed by waveguides 30 A, 20 and 30 B. Thus, system 10 exploits the change of the grating transfer function via applied electric fields in waveguides 30 A and 30 B to tune the resonant cavity wavelength and, correspondingly, the output spectrum of the entangled output photons P 1 and P 2 .
Entangled output photons P 1 and P 2 have a relatively narrow-line output spectrum as compared to entangled photons typically generated through SPDC mechanisms. According to Bragg's law, the grating reflection peaks when the light wavelength (λ), grating period (Λ), and the material refractive index (n) satisfy the condition λ B =2Λn, where λ B is the Bragg wavelength. The reflected spectrum bandwidth δλ=λ B -λ 0 is defined by the length of the grating (T) and its period: (δλ/λ B )=(Λ/T). Thus, the grating acts as an optical bandpass filter, or a mirror with a wavelength-dependent reflectivity. The dependence of the reflected light intensity on the wavelength is often referred to as the “transfer function” of the grating. The present invention exploits the ability to change the transfer function using an applied electric field in the end waveguides 30 A and 30 B to provide a narrowly tuned output spectrum for the outputted entangled photons P 1 and P 2 .
When the Bragg grating is embedded in an electro-optical material such as LiNbO 3 , the average refractive index of the media depends on the applied electric field (E). In this case, the Bragg-selected wavelength can be adjusted by changing the material refractive index with the external electric field. FIGS. 2 and 3 illustrate the Bragg wavelength dependence on the applied electric field.
To the best of the inventor's knowledge, all other commercially available tunable Bragg gratings use thermo-mechanical material expansion to change the grating period and, consequently, the Bragg wavelength. However, the LiNBO 3 gratings employed in the present invention are simple and have no moving parts. This allows for photon source system 10 to be tuned much quicker than prior art systems, i.e., faster than 1 nm/s, which is orders of magnitude quicker than prior art systems.
The resulting narrow-output linewidth of entangled photons P 1 and P 2 makes system 10 a good light source for performing long-distance QKD. It is also useful for entanglement-based QKD deployment in hybrid optical networks where quantum channels are wavelength multiplexed with classical (i.e., non-single-photon) channels. By varying the applied electric field in end waveguides 30 A and 30 B, the spectrum of the output photons can be rapidly tuned, which is a useful property for reconfigurable QKD networks. Note that for QKD applications, one or both of the outputted photons P 1 and P 2 and be used.
QKD System with Photon Source System
FIG. 4 is a schematic diagram of a QKD system 200 that includes a first QKD station Alice and a second QKD station Bob optically coupled via an optical fiber link FL. Alice includes photon source system 10 as described above. QKD system 200 is, for example, as described in the above-mentioned Bennett Patent, or in U.S. Pat. No. 7,102,121 to LaGasse, which patent is also incorporated by reference herein.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A robust, quickly tunable narrow-linewidth entangled photon source system based on Spontaneous Parametric Down Conversion (SPDC) of the pump light in periodically polled LiNbO 3 (PPLN) waveguides. The photon source provides narrow-linewidth, entangled output photons having a wavelength in the telecom C-Band wavelength. To tailor the output spectrum of the output photons, the PPLN waveguide is arranged between two end waveguides having LiNbO3-embedded Bragg gratings, thereby forming a tunable Fabry-Perot cavity. The resulting narrow output linewidth of the output photons makes the system desirable for use in a long-distance quantum key distribution (QKD) system. | 6 |
FIELD OF THE INVENTION
This invention relates to the field of labeling machines, and more particularly to machines for the automatic transfer of pressure sensitive adhesive coated labels to packages containing products or directly to the products.
BACKGROUND OF THE PRIOR ART
Identification of a product by the application of a printed label on the product itself or on the package in which the product is contained is an important part of marketing and of providing information to the purchaser. The label must be informative and it may be decorative to add to the appeal of the package. Among the most popular and versatile types of labels in use today are those which use a pressure sensitive adhesive and which are typically supplied to the manufacturer of the product on a release coated backing film from which the label may be stripped readily.
In some instances a sales package may be preprinted with the required information, but there are many cases in which preprinting is not practical. The addition of a label makes the packaging and identifying process more flexible and allows the use of a single type of bag or box for a number of different products, thereby reducing the manufacturer's investment in packaging materials.
One particular example of the need for flexibility is in the textile field where a variety of sizes or styles of garments, i.e. shirts, underwear, etc. are packaged in plastic bags which must be labeled differently for consumer information, store inventory information, and pricing. It is often practical to use the same type bag to hold different kinds of garments. The applying of different labels to bags of the same type and which contain different products allows the required flexibility.
In addition to the needed flexibility of being able to put different labels on the same type bag, there is also a need to apply labels on different types of bags which contain different types of product. Thus, if the same manufacturer were to package socks in a small bag and pajamas in a large bag, machine flexibility as to the position, orientation and size of both package and label is also useful. The ability to variably orient the bag and the label in relation to each other makes design and customization simpler and possibly more effective.
In the prior art, U.S. Pat. No. 4,270,968 for "LABELLING DEVICE", U.S. Pat. No. 4,392,913 for "LABELLING APPARATUS", and U.S. Pat. No. 4,676,859 for "LABELING APPARATUS" describe machines for labeling and relate to some aspects of the problem being addressed and are included herein by reference. While each of these patents teaches an aspect of handling and applying a label to a package containing a product, the present invention provides a novel machine and method for labeling automatically with several unique features.
It is an objective of the present invention to provide a labeling machine which will control and position the product package to which the label is to be applied.
Another objective of the present invention is to provide a machine that will reliably and automatically apply a label to a variety of different sized and shaped packages.
A further objective of the present invention is to provide a labeling machine which will place a label on a package in a variety of positions and orientations according to the design of the package.
An additional objective of the present invention is to provide a labeling machine which will adapt to and handle various sized labels.
A still further objective of the present invention is to provide a labeling machine which will control the feeding of the labels to the product package in a simple and effective manner.
The specific objectives mentioned above and others as will occur to the person skilled in the art will become apparent as the disclosure following is read.
SUMMARY OF THE INVENTION
The invention disclosed relates to an automatic labeling machine and method for use in placing a variety of labels on a variety of different sized and shaped packages in a manufacturing environment. The machine described incorporates a series of switches on the packaged product conveyor to sense the approach of the packages, interpose a positioning gate, and actuate a label transport system. The label is moved forward through a unique label stripper with its release backing until the driving mechanism is stopped by a signal from a photosensitive switch. The label is next picked up by a vacuum platen and applied to the surface of the package containing the product held at the gate. At the point of application, the vacuum, which is generated by a Venturi tube, is reversed to a blast of positive pressure to ensure proper adhesion of the label to the package.
While described in reference to labeling packages containing products, it is to be recognized that the automatic labeling machine and method of the invention may also be used for applying labels directly to the surfaces of products.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart which relates switch actions to machine actions in the method of labeling and operation of the labeling machine of the invention.
FIG. 2 is a schematic elevation view of the labeling machine illustrating the principal operative components of the invention which are typically supported by a frame, not shown.
FIG. 3 is a perspective depiction of a series of pressure sensitive labels as supplied on a typical release backing strip and illustrated passing between a light source and photosensitive switch positioned for use.
FIG. 4 is an enlarged detail elevation drawing of the label stripping device of the invention dispensing a label and the vacuum platen positioned to receive said label.
FIG. 5 is an enlarged perspective view of the label stripping device with a label projected therefrom.
FIG. 6A is a schematic drawing of the label stripping device adjusted to dispense the labels in an upwardly angled orientation.
FIG. 6B is a schematic drawing of the label stripping device adjusted to dispense the labels in a level orientation.
FIG. 6C is a schematic drawing of the label stripping device adjusted to dispense the labels in a downwardly angled orientation.
FIG. 7A is a sectional elevation drawing of the Venturi tube with an open solenoid valve so as to function to create a vacuum at a vacuum location.
FIG. 7B is a sectional elevation drawing of the Venturi tube with a closed solenoid valve so as to function to transmit a positive pressure at the prior vacuum location.
FIG. 8 is a bottom plan view of the vacuum label pickup platen.
FIG. 9 is a schematic plan drawing of the three way adjustable mounting apparatus of the labeling machine.
FIG. 10 is a schematic diagram of the electrical components used in the labeling machine system.
FIG. 11 is an exploded perspective view of the vacuum label pickup platen.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the flow chart which relates switch actions with corresponding machine actions as shown in FIG. 1 the sequence of operations of the labeling machine (illustrated in FIG. 2) of the present invention is outlined. A label may be applied by the labeling machine of the invention to either a box or a bag containing a product or to a product surface directly. The object to be labeled, for example a plastic bag containing a shirt, is brought to the labeling machine by a mechanical conveyor or a gravity conveyor chute which conforms fairly closely to the width dimension of the object.
The sequence of operations described below as shown in FIG. 1 is conducted by the labeling machine illustrated schematically in FIG. 2. The overall operating system of the labeling machine of FIG. 2 may be thought of as involving three interrelated systems which are actuated according to the series of controls briefly outlined above. One system is the product package PR conveyor system. A second system involves the movement of label L and backing B. A third system transfers label L from backing B to the product package PR.
In step A of the flow chart of FIG. 1, switch 12 senses the product package approaching the labeling position on the conveyor which action initiates the complete machine sequence. Switch 12 sends a signal to a product package positioning gate solenoid valve 16a which acts to close gate 16 which is adapted to stop the product package in a known location. Gate 16 is activated by the signal to block the path of the product package in a labeling position below a label applicator 20. Simultaneously, switch 12 also actuates electrical clutch CL/BR and vacuum initiating timer Tl. Clutch CL/BR couples a drive to a label advancing roller 60 so as to cause one label in a series of labels on a release backing to be advanced. The timer Tl operates and after a preset interval of time connects a vacuum source to platen 75 of the label applicator 20. The preset time interval is established in the example as 0.2 seconds to allow the label being advanced by the drive the time needed to arrive at the label applicator platen 75. When timer Tl acts to connect the vacuum source to the platen 75, the suction created picks up the label and holds it by the non-adhesive side, leaving the adhesive side exposed and facing toward the package containing the product.
The forward motion of labels and backing which was initiated by switch 12 in step A continues until stopped by photosensitive switch 56 in step D as discussed in greater detail below. The signal generated by photo switch 56 deactivates the clutch CL/BR and simultaneously activates a brake portion, stopping label motion.
When the package to be labeled is in labeling position against gate 16, switch 14 senses the product package PR in step B and signals the label applicator 20 which is holding the label by vacuum. The label applicator 20 descends by action of a linearly actuatable pneumatic cylinder. PG,8
Once platen 75 with the label is in close proximity to the product package, the vacuum which has been holding the label is no longer needed. When switch 14 caused the label applicator 20 to descend, it also started timer T2 to run for a cycle of 0.5 seconds. In step C timer T2 concludes its 0.5 second period and causes the direction of air flow through platen 75 to change from vacuum to pressure. This causes a rapid blast of air to exit platen 75 and positively release the label from platen 75 and onto the product. Reversing vacuum to pressure at platen 75 augments the primary mechanical force applying the label to the product package, thus overcoming the tendency of the label to remain on platen 75.
At the same time as timer T2 activates the air flow reversal from vacuum to pressure, it also causes the stroke of the label applicator 20 to reverse and return the platen 75 to the top position. Product position gate 16 is also reversed so as to open and allow the product package PR, now having been labeled, to pass.
In FIG. 2, conveyor 10, which may be a gravity chute or a driven conveyor, is configured with adjustable side plates so as to conform to the width of the product package PR. The width of conveyor 10 is adjusted so as to be sufficient to allow the product package PR to freely pass but close enough to the width of the product package PR to restrict significant lateral movement. The bed of conveyor 10 may be of any appropriate design, including rollers or air cushion friction relief. Conveyor 10 conveys the product package PR into a position to be labeled by the machine. Positioned adjacent conveyor 10 are product package approach switch 12, product package positioning gate 16 and product package position switch 14.
Conveyor 10 is illustrated in the preferred embodiment as a gravity chute mounted at an angle to the horizontal sufficient to allow product package PR to move smoothly to the appropriate position below the labeling machine to receive a label in a specified location. In other embodiments, such as a driven belt conveyor, conveyor 10 may be mounted horizontally. In either configuration switch 12, which acts to sense the approach of product package PR, is located adjacent conveyor 10 a distance from the desired labeling location greater than the length of product package PR. Product package positioning gate 16 is mounted adjacent conveyor 10 in a location so that, when closed, it will stop the forward movement of product package PR in the desired labeling location. Product package switch 14 is located adjacent conveyor 10 in a position to sense the presence of product package PR in the desired labeling position.
In operation, product package PR travels along conveyor 10 in the direction of the arrow. As product package PR actuates product package approach switch 12, switch 12 transmits a signal to solenoid valve 16a which conducts pressurized air so as to close gate 16. Position gate 16 is configured as a plurality of parallel rigid bars attached to a pneumatic cylinder and is mounted perpendicular to the plane of conveyor 10. Gate 16 when closed acts to block the travel of product package PR on conveyor 10, thus stopping each product package PR in a known position for repeatable, accurate label placement thereupon. When product package PR moves into position adjacent gate 16 for label application, product package position switch 14 closes. The signal generated by position switch 14 activates label applicator cylinder 20 by means of solenoid valve 20a and moves platen 75 downwardly to bring label L with its adhesive side facing product package PR into contact with product package PR so as to adhere to the surface thereof. Switches 12, 14 may be of a physical contact, photosensitive, or other style to detect the package or product to be labeled.
The labels which are correct for use in the machine and method disclosed herein are coated on a first side with a pressure sensitive adhesive and laminated onto a flexible backing sheet. Next the label material is printed on a second side and die cut to size, still adhered to the release backing. Die cutting will create an open space between labels and space all labels uniformly separated on the backing sheet. The space used in the preferred embodiment between adjacent labels is 0.125 inch (3.175 mm). The composition of the adhesive and the backing release coating, as is known in the manufacture of labels, are such that the adhesive coated label may be easily removed from the backing but it will stick firmly to other types of surface, particularly the product or package being labeled. The laminated labels and backing are then wound into a roll for mounting on the machine supply reel.
Labels L with backing B are transported from supply reel 64 through the machine. Supply reel 64 is driven by the tension on backing B as backing B is pulled forward by intermittently driven roller 60 in conjunction with idler 62. Roller 60 is driven through clutch/brake set CL/BR as discussed below. Reel 64 is equipped with a braking device (not shown) to prevent overspin and to maintain tension on backing strip B. The tension on backing B is desirable in order to properly strip label L from backing B and to keep backing B in a straight line between each pair of consecutive devices in its path through the labeling machine as will be further discussed. Backing B travels from supply reel 64 over idler 50 so that the segment of backing B beyond idler 50 is maintained in constant alignment regardless of the then current diameter of the supply quantity of backing B and labels L on reel 64. Takeup reel 66, driven by a slip clutch, winds up backing B from which labels L have been stripped.
After backing B and labels L pass idler 50, their path intersects a line between light source 54 and photosensitive switch 56 which devices are axially aligned with each other. Photosensitive switch 56 is adjustable in its degree of light sensitivity in a range at least sufficient so that the amount of light from light source 54 which passes through backing B alone will actuate switch 56 but the amount of light which passes through backing B plus label L is insufficient to so actuate.
FIG. 3 is a perspective representation of a series of labels L on backing B with light source 54 and photosensitive switch 56 operative thereupon. As it is illustrated, there is a gap separating each adjacent pair of labels L on backing B which gap creates a differential in light transmissibility which the photosensitive detection apparatus can sense and to which it can react. As backing strip B moves in the direction of the arrow and passes light beam 55 emitted by light source 54, the beam alternatingly impinges plain backing B and the combination of backing B plus label L. The difference in light transmissibility of the two alternating substrates results in differing amounts of light passing through. Photosensitive switch 56, which receives and responds to light beam 55 from light source 54, will therefore detect the end of each label L and generate a signal. The signal generated will actuate the brake portion of clutch/brake CL/BR and stop the movement of backing B and labels L. In the preferred embodiment, light source 54 is fiber optic unit lR23PMRA and photosensitive switch 56 is sensor OSBFV, both connected to power block OPBT2, all items supplied by Banner Electronics. Other types of signal generation and signal sensing capable of detecting label movement may be employed, such as electrical capacitance or light reflection.
A heater 58 (FIG. 2) is located between idlers 50, 52 and adjacent the path of backing B in close proximity thereto so as to warm the adhesive layer of label L. By so warming the adhesive, label L will release more easily from backing B and subsequently adhere more firmly to the product package PR when applied thereto and cooled. In the preferred embodiment heater 58 is an electric resistance type heater which operates continuously and has variable power input so as to enable regulation of the temperature achieved and thus the effect on the label adhesive.
After changing direction around idler 52, backing B next travels to and through label stripper 40 where each label L is removed from backing B. Label stripper 40 is shown in enlarged detail in FIGS. 4, 5, 6A, 6B, 6C. FIG. 5 shows label stripper 40 in perspective view as label L is being stripped and projected off backing strip B. Backing B is being pulled under tension in the direction of the arrow and passes under control bar 44 and approaches stripper bar 46. Backing B sharply reverses its direction of travel over the small radius of bar 46 as it passes around bar 46 while label L, due to its stiffness, continues moving forward in a straight line. Stripping label L from backing B by making a change in direction around a small radius has been made easier and more reliable by first warming the adhesive of label L by heater 58 as described above. As will be shown below, label L is now in position to be temporarily picked up by platen 75 (FIG. 4).
Label stripper 40 may be adjusted in its angular orientation to accommodate and properly strip various sizes and configurations of label. As illustrated in FIG. 5, stripper 40 is mounted on shafts 48a, 48b which may be centrally positioned as shown in the preferred embodiment or eccentrically positioned with respect to side plates 42. Shafts 48a, 48b are fixedly connected to the outward facing surfaces of each side plate 42 and are axially aligned with each other. Control bar 44 and stripper bar 46 are substantially parallel to each other and fixedly mounted to and between side plates 42. Bars 44, 46 are separated from each other by a distance at least sufficient to allow label L and backing B to pass therebetween. In the preferred embodiment, stripping bar 46 is 0.125 inch (3.175 mm) in diameter and control bar 44 is 0.1875 inch (4.7625 mm) in diameter. The center lines of bars 44, 46 are separated by 0.500 inch (12.7 mm). Whereas the preferred embodiment employs a pair of smooth surfaced, rigid, round bars, other cross sectional shapes may be used if desired. A support bearing (not shown) supports the outer end of shaft 48b. A split block locking clamp 49, which is tightened by thumbscrew 49a, supports the end of shaft 48a. By releasing locking clamp 49 so shaft 48a may be rotated, the relative positions of bars 44, 46 are adjusted as is depicted in FIGS. 6A, 6B, 6C. An alternate configuration wherein shafts 48a, 48b and stripper bar 46 are coaxial will function adequately to strip and position labels L with precision. The rotating of stripper 40 and repositioning of bars 44, 46 allows for precise adjustment of the projecting angle of label L as it separates from backing B. This obtains a fine control of the position of label L on platen 75 and subsequently on each product package PR. As will be understood by those skilled in the art, the ability to adjust the relative angle between label L and platen 75 is useful to adjust for accurate positioning of labels of different sizes and different degrees of stiffness. As will be seen by comparison of FIGS. 6A, 6B, 6C the degree of adjusting label stripping angle is substantial and reliable.
FIG. 4 illustrates that label L parts from backing B and is immediately taken up by the vacuum suction applied by tube 88 through platen 75. It is important when loading the machine with labels to orient the label supply roll so that the printed side of labels L will be closest to platen 75 and the adhesive side of label L is facing toward product package PR for adhesion thereto. Platen 75 is fixedly mounted to the free end of rod 22 of cylinder 20.
Returning to FIG. 2, after backing B has passed stripper 40 and label L has been transferred to platen 75, backing B continues toward mating rollers 60, 62 which are the sole means of tension and drive for the backing through the machine to that point. Roller 60 is driven intermittently by a motor through electrically operated clutch/brake set CL/BR. Roller 62 is an idler which presses against driven roller 60 so as to clamp and positively control backing B. When the brake is applied and the clutch is simultaneously released, rollers 60, 62 stop rotating and backing B stops moving. The braking device connected to supply reel 64 stops reel 64 from further rotation once roller 60 stops pulling backing B. Takeup roll 66, which functions to collect the stripped backing, is somewhat smaller in diameter than supply roller 64 due to the fact that backing B alone requires less volume to store after labels L have been removed. Takeup roller 66 will preferably be continuously urged to rotate by means of a slip clutch (not shown) connection so that roll 66 will maintain constant tension on backing B and wind up backing B when rolls 60, 62 move backing B forward. When rollers 60, 62 are stopped, roller 66 will be still and the slip clutch will continue to rotate. In construction of the labeling machine of the invention, the drive for roller 60 and takeup roll 66 may be derived from the same motor source and transmitted by chains, gears, etc. to the respective clutch/brake or slip drive unit or the like.
The vacuum for holding labels L to platen 75 is generated by Venturi tube 80 and transmitted by tube 88 as shown in detail in FIGS. 7A, 7B. The major function of Venturi tube 80 is the conventional operation of establishing a moderate vacuum by the use of a pressurized air flow as shown in FIG. 7A. By infusing pressurized air Pi into inlet 82 and out of outlet 84 as Po, an increase in diameters within the tube from inlet 82 to outlet 84 will cause a vacuum V to occur at the point that the internal diameter increases, which vacuum is transmitted to vacuum inlet 86. Inlet 86 is connected to platen 75 by tube 88 and the vacuum V thus created is transmitted to platen 75 to hold label L. In this way, a manufacturing facility that has a supply of pressurized air can simply create a moderate vacuum.
When label L is moved downward into label applying contact with the product package PR by label applicator pneumatic cylinder 20, Venturi solenoid valve 80a closes outlet 84 as seen in FIG. 7B. This valve closing causes the pressurized air Pi entering inlet 82 to be rapidly forced out through outlet 86. This air runs through tube 88 replacing vacuum suction to platen 75 and blowing label L off platen 75.
A further detail of the face of platen 75 is shown in FIGS. 8, 11, a bottom plan view and exploded assembly of platen 75. The vacuum which holds label L onto platen 75 is conducted to the surface through a series of small holes 77 in face plate 70. In the preferred embodiment, air passage holes 77 are configured as two segments, an inner rectangle 70a and an outer "L" shaped segment 70b. Ducts in channel plate 72 direct vacuum suction to segments 70a, 70b separately, with the duct to "L" shaped segment 70b able to be closed by valve 78. By this means, the vacuum may be applied to both segments 70a, 70b or to only the smaller rectangular segment 70a, allowing for an adjustment of the operative size of the vacuum surface to accommodate labels L of different sizes. In alternate embodiments, other numbers of groups of holes 77 may be configured having some or all of these groups controlled by shutoff valves.
FIG. 11 illustrates the inner workings of platen 75 by an exploded view. Platen 75 is comprised of three substantially flat plates of substantially similar external dimensions, face plate 70, channel plate 72 and connecting plate 74. Plates 70, 72, 74 are assembled by means of screws 71 which pass through holes 73a, 73b, 73c at each corner of the three plates with the holes 73a in face plate 70 being internally threaded to match the thread of screws 71. Plates 70, 72, 74 are assembled with interspersed gasket material or compound (not shown) to prevent air leaks.
Connecting plate 74 is fixedly attached to piston rod 22 of cylinder 20. Also attached in pneumatic communication through plate 74 are connecting tubes 76, 79 which are commonly connected to tube 88. Tube 79 is supplied from tube 88 through valve 78 which valve is operative to shut off the connection to tube 88.
Channel plate 72 has two holes formed therethrough, rectangular hole 72a and "L" shaped hole 72b, which holes are similarly sized and shaped to segments 70a, 70b of holes 77 through face plate 70. Thus, tube 76 is positioned in connecting plate 74 so that when plates 70, 72, 74 are pressed together in assembly, vacuum or air from tube 76 will flow through hole 74a in connecting plate 74 and through hole 72a in channel plate 72 and segment 70a of holes 77 in face plate 70. Similarly, tube 79 is positioned in connecting plate 74 so that when plates 70, 72, 74 are assembled, vacuum or air from tube 79 will flow through hole 74b in connecting plate 74 and through hole 72b in channel plate 72 and through segment 70b of holes 77 in face plate 70. When valve 78 is shut by appropriate control, not shown, vacuum or air will be supplied only to tube 76, hole 74a, hole 72a, and segment 70a, thus reducing the operative size of the face of platen 75.
As described above, the labeling machine of the present invention has substantial capability to adjust to accommodate labels of different size and different paper stiffness. The use of labels of a shape other than rectangular may be handled by using a portion of platen 75 as described and illustrated or by using a platen of similar concept but dissimilar physical configuration. As an example, a round label may be used with the present platen if it covers enough of the platen holes 77, or it may be better accommodated with a platen having a round pattern of holes.
Further, it may be required to place a label onto a package or product in a different orientation or location. If, for example, the primary labeling location were the lower left hand corner of the package or the product, one may have to place the label in the upper right hand corner. Alternatively, if the label were required to be rotated 90° or 180° , other means of adjustability are needed. The entire labeling machine of the invention is mounted on location adjusting units as shown in FIG. 9. The labeling machine is mounted on turntable 90 which is able to be rotated and locked in increments of 90° . Other degrees of angular adjustability could be adapted, as well. The labeling machine is placed on turntable 90 so label applicator 20 is radially beyond the periphery of turntable 90 and can descend to apply labels to product package PR without interference as may be needed in any orientation. A representative placement for the labeling machine is indicated by the location of applicator 20, shown in dashed lines, as will allow labels to be applied to a package product below the mounting apparatus.
Turntable 90 is supported on linear traverse nuts 92 which travel along lead screws 94 when screws 94 are rotated. Lead screws 94 are actuated by a common drive (not shown) so as to impart motion to both nuts 92 simultaneously, causing turntable 90 with the labeling machine to move along a path parallel to screws 94. The ends of each lead screw 94 are mounted into cross blocks 98 which have low friction bearings adapted to hold screws 94 and allow them to rotate freely. In holes perpendicular to the bearings of blocks 98 are internal lead threads which match the threads of transverse lead screws 96. Screws 96 are similarly commonly driven. Thus, it is seen that rotation of screws 96 moves the labeling machine mounted on turntable 90 in a "X" linear direction, rotation of screws 94 moves the machine in a "Y" linear direction and rotation of turntable 90 moves the machine angularly. Therefore, the objectives of label placement versatility are accomplished. Actuation of the turntable or lead screws by pairs is done according to the preferred embodiment by means of crank arms, each shaft having a locking ability. Alternate means, such as a motorized screw drive may likewise be employed.
FIG. 10 portrays the electrical control circuit for the machine functions described. The illustrated circuit enables a voltage source on the left side to be connected to ground on the right side when all the switches in a connecting horizontal line are closed. Switch 12 (which senses the approach of product package PR) closes to actuate product package position gate solenoid valve 16a and vacuum timer Tl through normally closed switch 32. Valve 16a closes product package position gate 16 and vacuum is actuated at the completion of the cycle of timer Tl by solenoid valve 80a actuating Venturi tube 80. Switch 12 also activates counter Cl and the clutch part of the clutch/brake set CL/BR through normally closed photo switch 56. Alternate initiation of label advancement, such as label applicator 20 returning to its top position, may be employed. When counter Cl goes from zero to one and photo switch 56 senses the end of label L, switch 56 opens, signifying the passing of a single label, and reverses clutch/brake CL/BR from clutch function to brake function, stopping label L. Counter Cl may be any device to restrict actuation of backing B so only a single label L is advanced each cycle.
When product package PR stops at the labeling position adjacent gate 16, product package PR is sensed by switch 14 which closes, energizing label applicator cylinder 20 by solenoid valve 20a and timer T2 through normally closed switch 32'. Solenoid 20a causes applicator 20 to descend. Timer T2 runs through its cycle and when completed closes switch 15 which actuates relay R. Relay R opens normally closed switches 32, 32'. As seen above, switch 32 will open to open gate 16 through solenoid 16a and reverse vacuum to pressure by solenoid 80a. Switch 32' will cause label applicator 20 to be raised by action of solenoid 20a.
The electrical actions described here, in practical application are augmented by relays to affect the machine actions needed. Alternatively, the electrical system may be manifest in a fixed or programmable logic circuit. Such description is here omitted to concentrate on principles.
Whereas the major components and their operative relationships were described herein in schematic form, it is to be understood that the actual machine is constructed about a frame which serves to support and to contain the various devices.
Having disclosed the present invention by means of a preferred embodiment, it is to be understood by those skilled in art that other possible variations may be developed. The example used herein is, therefore, not to be construed as a limitation of the principles and the scope of the invention. | A labeling machine is provided for the automatic transfer of labels with a pressure sensitive adhesive from a release backing to the surface of a package containing a product or to the surface of a product (hereinafter referred to as the "product". The labeling machine comprises a product transport system, a label transport system and a label transfer system. The product transport system moves the product into a labeling position. The label transport system moves labels which are on a backing from a supply reel, through a label stripper to separate the labels from the backing, and the backing continues to a takeup reel. The label transfer system picks up the labels stripped by the label stripper on a vacuum platen and applies the labels to the products being so identified. | 1 |
FIELD OF THE DISCLOSURE
This disclosure relates generally to laundry treating appliances, and, more particularly, to laundry treating appliances and methods of controlling the same to determine an end-of-cycle condition.
BACKGROUND
Laundry treating appliances, such as a clothes washer, a clothes dryer, a combination washer-dryer, a refresher and a non-aqueous system, may have a configuration based on a rotating drum that defines a treating chamber in which laundry items are placed for treating according to a cycle of operation. A dispensing system may be provided for dispensing a treating chemistry as part of the cycle of operation. A controller may be operably connected with the dispensing system and may have various components of the laundry treating appliance to execute the cycle of operation. The cycle of operation may be selected manually by the user or automatically based on one or more conditions determined by the controller.
SUMMARY
A disclosed example method of operating a laundry treating appliance having a treating chamber in which laundry is received for treatment, and a heated air system having a supply conduit coupled to the treating chamber and an exhaust conduit coupled to the treating chamber includes supplying heated air to the treating chamber via the supply conduit, exhausting air from the treating chamber via the exhaust conduit, repeatedly determining exhaust air temperatures of the air exhausted from the exhaust conduit, determining a windowed derivative of the exhaust air temperature values, determining a zero crossing of the windowed derivative, and initiating the termination of the supplying of heated air in response to the determination of the zero crossing.
A disclosed example laundry treating appliance includes a treating chamber in which laundry is to be received for treatment, a heated air system having a supply conduit to supply heated air to the treating chamber, and an exhaust conduit to exhaust air from the treating chamber, a sensor to determine exhaust air temperatures of the air exhausted via the exhaust conduit, and a controller programmed to determine a windowed derivative of the exhaust air temperature values, determine a zero crossing of the windowed derivative, and initiate the termination of the supplying of heated air in response to the determination of the zero crossing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph depicting example exhaust air temperature profiles.
FIG. 2 is a schematic view of an example laundry treating appliance in the form of a clothes dryer.
FIG. 3 is a schematic view of an example manner of implementing the example controller of FIG. 2 .
FIG. 4 is a flow chart illustrating an example method of determining an end of cycle condition.
FIG. 5 is a graph depicting example slope curves corresponding to the example exhaust temperature profiles of FIG. 1 .
FIG. 6 is a graph depicting example slope derivative curves corresponding to the example slope curves of FIG. 5 .
DETAILED DESCRIPTION
The state or point in a drying cycle when substantially all moisture has evaporated from the surface of the fabric in a laundry load, and the input heat energy primarily raises the temperature of the fabric, is known as critical moisture content state or point. As shown in FIG. 1 , the slope of the temperature profile undergoes a significant increase past this critical moisture content point 100 compared to the preceding period when there is moisture present on the fabric surface. In FIG. 1 , three temperature profiles 105 , 110 , 115 are shown corresponding to a 1 kilogram (kg) load, a 4 kg load and an 8 kg load, respectively. After determining the change in slope, remaining time needed for the drying process to finish can be determined using a load mass determined using load sensing or some other method. Also, after determining the critical moisture content state or point, the end of cycle behavior can be adjusted by, for example, lowering input power/usage of main actuators such as drum (speed), blower fan (speed), heater (temperature, duty cycle, electric power) to save energy and prevent overheating and/or over drying of the fabric. By more accurately determining the critical moisture content state or point, the examples disclosed herein may achieve greater energy savings, reduce the over drying of fabrics, provide better fabric care through cycle termination at a lower temperature, and/or can display a more accurate indication of the remaining cycle time. Because the examples disclosed herein can determine the critical moisture content state or point using only drum exhaust air temperature, the disclosed examples may be implemented without the complexity and cost of moisture sensing strips, inlet air temperature sensors, and/or humidity sensors. As used herein, “determining” means any manner, direct or indirect, by any actor, human or machine, by which a parameter or condition may be decided, which includes, without limitation sensing, calculating, estimating, experimenting, empirically, theoretically, mathematically, identifying, detecting, computing, measuring, reading an output of a sensor, and reading a sensor output from a memory.
FIG. 2 is a schematic view of an example laundry treating appliance 10 in the form of a clothes dryer 10 . The clothes dryer 10 described herein shares many features of a traditional automatic clothes dryer, which will not be described in detail except as necessary for a complete understanding of this disclosure. While examples are described in the context of a clothes dryer 10 , the examples disclosed herein may be used with any type of laundry treating appliance, non-limiting examples of which include a washing machine, a combination washing and drying machine, a non-aqueous system, and a refreshing/revitalizing machine.
As illustrated in FIG. 2 , the clothes dryer 10 may include a cabinet 12 in which is provided a controller 14 that may receive input from a user through a user interface 16 for selecting a cycle of operation and controlling the operation of the clothes dryer 10 to implement the selected cycle of operation. As discussed in more detail below, the controller 14 may be programmed and/or configured to determine an end-of-cycle condition based on drum exhaust air temperatures, and to terminate and/or adjust drying based on the determined end-of-cycle condition.
The cabinet 12 may be defined by a front wall 18 , a rear wall 20 , and a pair of side walls 22 supporting a top wall 24 . A chassis may be provided with the walls being panels mounted to the chassis. A door 26 may be hingedly mounted to the front wall 18 and may be selectively movable between opened and closed positions to close an opening in the front wall 18 , which provides access to the interior of the cabinet 12 .
A rotatable drum 28 may be disposed within the interior of the cabinet 12 between opposing stationary front and rear bulkheads 30 , 32 , which, along with the door 26 , collectively define a treating chamber 34 for treating laundry. As illustrated, and as is the case with most clothes dryers, the treating chamber 34 is not fluidly coupled to a drain. Thus, any liquid introduced into the treating chamber 34 may not be removed merely by draining.
Non-limiting examples of laundry that may be treated according to a cycle of operation include, a hat, a scarf, a glove, a sweater, a blouse, a shirt, a pair of shorts, a dress, a sock, a pair of pants, a shoe, an undergarment, and a jacket. Furthermore, textile fabrics in other products, such as draperies, sheets, towels, pillows, and stuffed fabric articles (e.g., toys), may be treated in the clothes dryer 10 .
The drum 28 may include at least one lifter 29 . In most dryers, there may be multiple lifters. The lifters may be located along an inner surface of the drum 28 defining an interior circumference of the drum 28 . The lifters may facilitate movement of the laundry 36 within the drum 28 as the drum 28 rotates.
The drum 28 may be operably coupled with a motor 54 to selectively rotate the drum 28 during a cycle of operation. The coupling of the motor 54 to the drum 28 may be direct or indirect. As illustrated, an indirect coupling may include a belt 56 coupling an output shaft of the motor 54 to a wheel/pulley on the drum 28 . A direct coupling may include the output shaft of the motor 54 coupled to a hub of the drum 28 .
An air system may be provided to the clothes dryer 10 . The air system supplies air to the treating chamber 34 and exhausts air from the treating chamber 34 . The supplied air may be heated or not. The air system may have an air supply portion that may form, in part, a supply conduit 38 , which has one end open to ambient air via a rear vent 37 and another end fluidly coupled to an inlet grill 40 , which may be in fluid communication with the treating chamber 34 . A heating element 42 may lie within the supply conduit 38 and may be operably coupled to and controlled by the controller 14 . If the heating element 42 is turned on, the supplied air will be heated prior to entering the drum 28 .
The air system may further include an air exhaust portion that may be formed in part by an exhaust conduit 44 . A lint trap 45 may be provided as the inlet from the treating chamber 34 to the exhaust conduit 44 . A blower 46 may be fluidly coupled to the exhaust conduit 44 . The blower 46 may be operably coupled to and controlled by the controller 14 . Operation of the blower 46 draws air into the treating chamber 34 as well as exhausts air from the treating chamber 34 through the exhaust conduit 44 . The exhaust conduit 44 may be fluidly coupled with a household exhaust duct (not shown) for exhausting the air from the treating chamber 34 to the outside of the clothes dryer 10 .
The air system may further include various sensors and other components, such as a thermistor 47 and a thermostat 48 , which may be coupled to the supply conduit 38 in which the heating element 42 may be positioned. The thermistor 47 and the thermostat 48 may be operably coupled to each other. Alternatively, the thermistor 47 may be coupled to the supply conduit 38 at or near to the inlet grill 40 . Regardless of its location, the thermistor 47 may be used to aid in determining an inlet temperature. A thermistor 51 and a thermal fuse 49 may be coupled to the exhaust conduit 44 . The thermistor 51 may be used to determine an outlet or exhaust air temperature.
A moisture sensor 50 may be positioned in the interior of the treating chamber 34 to monitor the amount of moisture of the laundry in the treating chamber 34 . One example of a moisture sensor 50 is a conductivity strip. The moisture sensor 50 may be operably coupled to the controller 14 such that the controller 14 receives output from the moisture sensor 50 . The moisture sensor 50 may be mounted at any location in the interior of the dispensing dryer 10 such that the moisture sensor 50 may be able to accurately sense the moisture content of the laundry. For example, the moisture sensor 50 may be coupled to one of the bulkheads 30 , 32 of the drying chamber 34 by any suitable means.
A dispensing system 57 may be provided to the clothes dryer 10 to dispense one or more treating chemistries to the treating chamber 34 according to a cycle of operation. As illustrated, the dispensing system 57 may be located in the interior of the cabinet 12 although other locations are also possible. The dispensing system 57 may be fluidly coupled to a water supply 68 . The dispensing system 57 may be further coupled to the treating chamber 34 through one or more nozzles 69 . As illustrated, nozzles 69 are provided to the front and rear of the treating chamber 34 to provide the treating chemistry or liquid to the interior of the treating chamber 34 , although other configurations are also possible. The number, type and placement of the nozzles 69 are not germane to this disclosure.
As illustrated, the dispensing system 57 may include a reservoir 60 , which may be a cartridge, for a treating chemistry that is releasably coupled to the dispensing system 57 , which dispenses the treating chemistry from the reservoir 60 to the treating chamber 34 . The reservoir 60 may include one or more cartridges configured to store one or more treating chemistries in the interior of cartridges. A suitable cartridge system may be found in U.S. Pub. No. 2010/0000022 to Hendrickson et al., filed Jul. 1, 2008, entitled “Household Cleaning Appliance with a Dispensing System Operable Between a Single Use Dispensing System and a Bulk Dispensing System,” which is herein incorporated by reference in its entirety.
A mixing chamber 62 may be provided to couple the reservoir 60 to the treating chamber 34 through a supply conduit 63 . Pumps such as a metering pump 64 and delivery pump 66 may be provided to the dispensing system 57 to selectively supply a treating chemistry and/or liquid to the treating chamber 34 according to a cycle of operation. The water supply 68 may be fluidly coupled to the mixing chamber 62 to provide water from the water source to the mixing chamber 62 . The water supply 68 may include an inlet valve 70 and a water supply conduit 72 . It is noted that, instead of water, a different treating chemistry may be provided from the exterior of the clothes dryer 10 to the mixing chamber 62 .
The treating chemistry may be any type of aid for treating laundry, non-limiting examples of which include, but are not limited to, water, fabric softeners, sanitizing agents, de-wrinkling or anti-wrinkling agents, and chemicals for imparting desired properties to the laundry, including stain resistance, fragrance (e.g., perfumes), insect repellency, and UV protection.
The dryer 10 may also be provided with a steam generating system 80 that may be separate from the dispensing system 57 or integrated with portions of the dispensing system 57 for dispensing steam and/or liquid to the treating chamber 34 according to a cycle of operation. The steam generating system 80 may include a steam generator 82 fluidly coupled with the water supply 68 through a steam inlet conduit 84 . A fluid control valve 85 may be used to control the flow of water from the water supply conduit 72 between the steam generating system 80 and the dispensing system 57 . The steam generator 82 may further be fluidly coupled with the one or more supply conduits 63 through a steam supply conduit 86 to deliver steam to the treating chamber 34 through the nozzles 69 . Alternatively, the steam generator 82 may be coupled with the treating chamber 34 through one or more conduits and nozzles independently of the dispensing system 57 .
The steam generator 82 may be any type of device that converts the supplied liquid to steam. For example, the steam generator 82 may be a tank-type steam generator that stores a volume of liquid and heats the volume of liquid to convert the liquid to steam. Alternatively, the steam generator 82 may be an in-line steam generator that converts the liquid to steam as the liquid flows through the steam generator 82 .
It will be understood that the details of the dispensing system 57 and steam generating system 80 are not germane to this disclosure and that any suitable dispensing system and/or steam generating system may be used with the dryer 10 . It is also within the scope of this disclosure for the dryer 10 to not include a dispensing system or a steam generating system.
FIG. 3 is a schematic view of an example manner of implementing the example controller 14 of FIG. 2 . As shown in FIG. 3 , the controller 14 is coupled to various components of the dryer 10 . The controller 14 may be communicably coupled to components of the clothes dryer 10 such as the heating element 42 , the blower 46 , the thermistor 47 , the thermostat 48 , the thermal fuse 49 , the thermistor 51 , the moisture sensor 50 , the motor 54 , the inlet valve 70 , the pumps 64 , 66 , the steam generator 82 and the fluid control valve 85 to either control these components and/or receive their input for use in controlling the components. The controller 14 is also operably coupled to the user interface 16 to receive input from the user through the user interface 16 for the implementation of the drying cycle and provide the user with information regarding the drying cycle. An example method that may be carried out by the controller 14 to determine an end-of-cycle condition, and to terminate and/or adjust a drying processed based on the end-of-cycle condition is described below in connection with FIG. 4 .
The user interface 16 may be provided having operational controls such as dials, lights, knobs, levers, buttons, switches, and displays enabling the user to input commands to a controller 14 and receive information about a treatment cycle from components in the clothes dryer 10 or via input by the user through the user interface 16 . The user may enter many different types of information, including, without limitation, cycle selection and cycle parameters, such as cycle options. Any suitable cycle may be used. Non-limiting examples include, Casual, Delicate, Super Delicate, Heavy Duty, Normal Dry, Damp Dry, Sanitize, Quick Dry, Timed Dry, and Jeans.
The controller 14 may implement a treatment cycle selected by the user according to any options selected by the user and provide related information to the user. The controller 14 may also comprise a central processing unit (CPU) 74 and an associated memory 76 where various treatment cycles and associated data, such as look-up tables, may be stored. One or more software applications, such as an arrangement of executable machine-readable commands/instructions may be stored in the memory and executed by the CPU 74 to implement, perform and/or otherwise carry-out the one or more treatment cycles. Example machine-readable instructions that may be executed by the CPU 74 to determine an end-of-cycle condition, and to terminate and/or adjust a drying process based on the end-of-cycle condition are discussed below in connection with FIG. 4 .
In general, the controller 14 will effect a cycle of operation to effect a treating of the laundry in the treating chamber 34 , which may or may not include drying. The controller 14 may actuate the blower 46 to draw an inlet air flow 58 into the supply conduit 38 through the rear vent 37 when air flow is needed for a selected treating cycle. The controller 14 may activate the heating element 42 to heat the inlet air flow 58 as it passes over the heating element 42 , with the heated air 59 being supplied to the treating chamber 34 . The heated air 59 may be in contact with a laundry load 36 as it passes through the treating chamber 34 on its way to the exhaust conduit 44 to effect a moisture removal of the laundry. The heated air 59 may exit the treating chamber 34 , and flow through the blower 46 and the exhaust conduit 44 to the outside of the clothes dryer 10 . The controller 14 continues the cycle of operation until completed. If the cycle of operation includes drying, the controller 14 determines when the laundry is dry. FIGS. 4-6 illustrate an example method of determining when laundry is dry.
During a cycle of operation, one or more treating chemistries may be provided to the treating chamber 34 by the dispensing system 57 as actuated by the controller 14 . To dispense the treating chemistry, the metering pump 64 is actuated by the controller 14 to pump a predetermined quantity of the treating chemistry stored in the cartridge 60 to the mixing chamber 62 , which may be provided as a single charge, multiple charges, or at a predetermined rate, for example. The treating chemistry may be in the form of a gas, liquid, solid, gel or any combination thereof, and may have any chemical composition enabling refreshment, disinfection, whitening, brightening, increased softness, reduced odor, reduced wrinkling, stain repellency or any other desired treatment of the laundry. The treating chemistry may be composed of a single chemical, a mixture of chemicals, or a solution of a solvent, such as water, and one or more chemicals.
FIG. 4 is a flow chart of an example method to determine an end-of-cycle condition and terminate and/or adjust drying of laundry based on the determined end-of-cycle condition. A processor, a controller and/or any other suitable processing device such as the example CPU 74 may be used, configured and/or programmed to execute and/or carry out the example method of FIG. 4 . For example, the example method of FIG. 4 may be embodied in program code and/or machine-readable instructions stored on a tangible computer-readable medium such as the memory 76 . Many other methods of implementing the example method of FIG. 4 may be employed. For example, the order of execution may be changed, and/or one or more of the blocks and/or interactions described may be changed, eliminated, sub-divided, or combined. Additionally, any or all of the example method of FIG. 4 may be carried out sequentially and/or carried out in parallel by, for example, separate processing threads, processors, devices, discrete logic, circuits, etc.
As used herein, the term “tangible computer-readable medium” is expressly defined to include any type of computer-readable medium and to expressly exclude propagating signals. As used herein, the term “non-transitory computer-readable medium” is expressly defined to include any type of computer-readable medium and to exclude propagating signals. Example tangible and/or non-transitory computer-readable medium include a volatile and/or non-volatile memory, a volatile and/or non-volatile memory device, a flash memory, a read-only memory (ROM), a random-access memory (RAM), a programmable ROM (PROM), an electronically-programmable ROM (EPROM), and/or an electronically-erasable PROM (EEPROM).
The method of FIG. 4 starts with the controller 14 waiting a pre-determined amount of time t start to allow the clothes dryer 10 to reach an initial equilibrium (block 405 ). The controller 14 determines at time t start a reference temperature T o such as an ambient temperature (block 410 ), and begins periodically determining (e.g., measuring) exhaust air temperatures using, for example, the example thermistor 51 (block 415 ). Example exhaust air temperatures 105 , 110 and 115 are shown in FIG. 1 for 1 kg, 4 kg and 8 kg laundry masses, respectively.
The controller 14 determines (e.g., computes) a slope of the exhaust air temperatures by computing a difference between a current exhaust air temperature T e and the reference temperature T o , and computing a product of the difference and an inverse of the time t at which the exhaust air temperature T e was determined (block 420 ). The slope of the exhaust air temperatures can be expressed mathematically as
s ( t ) = T e - T o t . EQN ( 1 )
Because the slope expressed in EQN (1) is computed with reference to the reference temperature T o determined at t start and with a denominator of t, the slope of EQN (1) does not represent a conventional piecewise derivative of the exhaust air temperatures. Example slopes 505 , 510 and 515 corresponding to the example exhaust air temperature profiles 105 , 110 and 115 of FIG. 1 are shown in FIG. 5 . As shown in FIG. 5 , the slopes 505 , 510 and 515 have a local minima corresponding to the critical moisture content points 100 of FIG. 1 . In some examples, a slope value is determined as each exhaust air temperature is determined.
Returning to FIG. 4 , to determine (e.g., identifies) the local minima of the slope, the example controller 14 determines (e.g., computes) a derivative of the slope values. A zero-crossing of the slope derivative corresponds to a local minima of the slope. Because the exhaust air temperatures are typically noisy, the slope values will be noisy. To substantially mitigate false determination of a zero-crossing, the derivative of the slope is determined using slope values spaced apart by a window t w . Accordingly, the controller 14 waits until enough initial slope values have been determined before beginning to determine derivatives of the slope (block 425 ).
Once enough slope values have been determined, the controller 14 begins determining slope derivative values (block 430 ). In some examples, a new slope derivative value is determined as each slope value is determined. The controller 14 determines (e.g., computes) a slope derivative value by computing a difference between two slope values that are spaced apart by the window t w , which is selected to reduce the occurrence of false zero-crossings, and computing a product of the difference and the inverse of the window t w . The slope derivative can be expressed mathematically as
derivative
=
s
(
t
)
-
s
(
t
-
t
w
)
t
w
.
EQN
(
2
)
An example value of the window t w is 250 seconds. Because the example derivative of EQN (2) uses slope values spaced apart by the window t w , the derivative of EQN (2) is referred to herein as a “windowed derivative.” In contrast, a conventional derivative is mathematically expressed as
s ′ ( t ) = s ( t ) - s ( t - Δ t ) Δ t , EQN ( 3 )
where Δt is a small value that is substantially smaller than the window t w . The use of a conventional derivative would lead to infrequent false zero-crossing determinations. Example slope derivatives 605 , 610 and 615 corresponding to the example slopes 505 , 510 and 515 of FIG. 5 are shown in FIG. 6 . As shown in FIG. 6 , the slope derivatives 606 , 610 and 615 have a zero-crossing corresponding to the critical moisture content points 100 of FIG. 1 .
Returning to FIG. 4 , when the slope derivative of EQN (2) is substantially equal to zero (block 435 ), the controller 14 determines (e.g., estimates) the mass of the laundry in the laundry drying appliance 14 using, for example, a weight and/or volume sensor (block 440 ). Based on the determined load mass, the controller 14 determines an additional amount of time and/or parameters to complete the current drying cycle (block 445 ). For example, a large load (e.g., approximately 8 kg) will be dried for an additional 10 minutes, while a small load (e.g., approximately 1 kg) will be dried for an additional 3 minutes. The controller 14 completes the drying cycle based on the determined time and/or parameters (block 450 ), and control exits from the example method of FIG. 4 .
Returning to block 435 , if the derivative slope is not substantially equal to zero (block 435 ), control returns to block 415 to determine another outlet air temperature.
Returning to block 425 , if not enough slope values have been determined to enable the determination of derivative slope values (block 425 ), control returns to block 415 to determine another air temperature and determine another slope value.
To the extent not already described, the different features and structures of the various embodiments may be used in combination with each other as desired. That one feature may not be illustrated in all of the embodiments is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different embodiments may be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described.
Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the claims of this patent. | Laundry treating appliances and methods of controlling the same to determine an end-of-cycle condition are disclosed. An example method of operating a laundry treating appliance having a treating chamber in which laundry is received for treatment, and a heated air system having a supply conduit coupled to the treating chamber and an exhaust conduit coupled to the treating chamber includes supplying heated air to the treating chamber via the supply conduit, exhausting air from the treating chamber via the exhaust conduit, repeatedly determining exhaust air temperatures of the air exhausted from the exhaust conduit, determining a windowed derivative of the exhaust air temperature values, determining a zero crossing of the windowed derivative, and initiating the termination of the supplying of heated air in response to the determination of the zero crossing. | 3 |
This application is a continuation, of application Ser. No. 07/391420, filed 8/9/89 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to transmission mounting device and more particularly to a shock and vibration damping system for transmissions such as marine transmissions.
2. Background Art
Various mounting systems have heretofore been employed for transmissions. German patent document DE OS 35 16 903, illustrated a transmission damping and positioning system which included a rigid bearing upon which the transmission was centrally supported in combination with laterally spaced yieldable mounts. The yieldable mounts comprised, for example, rubber buffers, springs, or shock absorbers and served to attenuate vibrations, changes in torque loads, structure borne vibrations and accompanying noises. In addition, the yieldable mounts also compensated for structural changes in the supporting base relative to the transmission. For example, a ship's hull was subject to deformation which resulted in variations between the relative positions of the ship's drive system including transmissions, motors and the bearings for the ship's screw shafts.
These structural deformations frequently led to damage of drive system components. As a result, the ship's screw shafts were required to be interconnected to transmissions through elastic couplings. The couplings utilized were relatively large, heavy and costly.
Due to the necessity of reducing relative displacement between drive system components, prior transmission bearings were required to be relatively hard. Transmission vibration, deformations of the hull, torque shocks or impacts from the motor or from the ship's screw shafts resulted in relatively significant positional changes of the transmission with respect to the remaining drive system components when yieldable elastic components were used for bearings.
The utilization of relatively hard bearings permitted compensation of some of the positional changes of the drive system components relative to one another. Utilization of relatively hard bearings did not adequately provide for noise attenuation or adequately compensate for system shocks. The degree of permitted elasticity was limited since excessive elasticity resulted in damage to the transmission, the motor or the screw shaft due to the relative movement of the components.
As a result of the conflicting requirements for transmission mounting systems, known mounting systems, at best, provided but a compromise with respect to desired results.
SUMMARY OF THE INVENTION
Briefly, the present invention comprises a damping and positioning transmission mount system which includes a plurality of adjustable support units. The support units are positioned between a transmission and support or reference surfaces. Each support unit includes an elastic bearing which is readily deformable in a support direction and a hydraulic spacing link which is extensible and retractible in the support direction. Both the bearing and the spacing link are arranged in tandem, i.e. one after the other, between the support surface and the transmission.
Sensors are provided for indicating changes in the distance between the transmission and the support or reference surface at each adjustable support unit due to deformation of the elastic bearing. A control unit connected to the sensors actuates a hydraulic circuit to provide compensating changes in the length of each spacing link to maintain the distance between the transmission and the support or reference surface substantially constant regardless of the dimensional changes of the elastic bearings.
From the foregoing compendium, it will be appreciated that it is an aspect of the present invention to provide a compensating transmission positioning system of the general character described which is not subject to the disadvantages of the background art aforementioned.
A consideration of the present invention is to provide a compensating drive system component positioning system of the general character described which achieves superior shock and vibration attenuation while preventing excessive displacement between drive system components.
A feature of the present invention is to provide a compensating transmission positioning system of the general character described which facilitates the usage of readily deformable bearings for improved shock, torque load and vibration attenuation without the associated disadvantages which would normally result from employment of readily deformable bearings.
Another feature of the present invention is to provide a compensating transmission positioning system of the general character described which includes a control system having a feed back loop for maintaining the position of a transmission relative to engaged drive system components.
Yet another feature of the present invention is to provide a compensating transmission positioning system of the general character described which includes a high degree of vibration and shock attenuation while minimizing relative displacement between drive system components.
Other aspects, features and considerations in part will be obvious and in part will be pointed out hereinafter.
With these ends in view, the invention finds embodiment in the various combinations of elements, arrangements of parts and series of steps by which the said aspects, features and considerations and certain other aspects, features and considerations are attained, all with reference to the accompanying drawings and the scope of which is more particularly pointed out and indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, in which is shown one of the various possible exemplary embodiments of the invention,
FIG. 1 is a schematized front elevational view of a compensating transmission mount system constructed in accordance with and embodying the invention and illustrating a typical marine transmission and a plurality of support units positioned between the transmission and a horizontal support surface;
FIG. 2 is a schematized plan view of the transmission and showing a pair of lateral reference surfaces with a support unit being positioned between the transmission and each lateral reference surface; and
FIG. 3 is a schematized enlarged scale vertical sectional view through a support unit and showing a representation of a hydraulic circuit which is controlled to provide compensating changes in the length of a spacing link which forms part of the support unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings, the reference numeral 5 denotes generally a transmission mount system constructed in accordance with and embodying the invention. The transmission mount system is configured to support and maintain the position of a transmission 2 which may comprise a component of a marine drive system.
The transmission 2, illustrated in schematized format in FIG. 1, includes three shafts, 3, 9, and 11 which rotate about axes 14, 8 and 15 respectively. By way of example, the shaft 11 may be driven by a ship motor; the shaft 3 is employed drives a screw shaft and the shaft 9 carries an intermediate gear. Alternately, the shaft 9 may be driven by the motor while the shaft 3 drives the screw shaft. The shaft 11 may be employed as a power take off output shaft for driving additional drive system or ship components such as oil pumps, generators, etc.
The transmission mount system 5 includes four vertical support units 6 which extend between a horizontal mounting flange 17 of the transmission 2 and a horizontal support surface of a base 4. From an observation of FIG. 2 it will be noted that the base 4 also includes a pair of lateral support surfaces 10 between which the transmission mounting flange 17 is positioned. Extending between each of the lateral support surfaces 10 and parallel surfaces of the transmission mounting flange 17, is a support unit 12, substantially identical in construction to the support units 6 previously mentioned.
It should be noted that the transmission mounting flange 17 includes at midlength, a forwardly projecting leg 19 and a rearwardly projecting leg 20, each of which engage a support unit 6. Similarly, a pair of legs 23, 25 project from the flange 17 at the right and left ends of the transmission.
Positioned near each end leg 23, 25 adjacent the front and rear of the flange 17, is a distance sensor 7. Similarly, extending between the flange 17 and the lateral support surfaces 10 and in close proximity to each support unit 12 is a further distance sensor 13. The distance sensors 7, 13 monitor the position of the flange 17 hence the transmission 2 relative to all support surfaces at the respective support units.
In accordance with the invention, an electronic control unit 16 which may comprise, for example, a microprocessor, receives, from each of the sensors 7, 13, signals indicating the measured distance between the transmission and the support surfaces at the respective associated support units, 6, 12 and/or signals indicating changes in such distances.
The control unit 16 generates signals for actuating a separate servo valve 18 which is associated with each support unit 6, 12 for controlling such support unit to provide a compensating adjustment.
Turning now to FIG. 3 wherein an enlarged scale cross sectional illustration of a typical support unit 6 is shown, it should be appreciated that the support unit 6 includes an elastic bearing 50 which comprises a sandwich or laminate formed of a plurality of plates 52, 54, 56 between which a pair of deformable elastic slabs 58 are positioned. The elastic slabs 58 preferably are yieldable under both compressive and tensile stresses. It should also be noted that the elastic bearing 50 rests on the horizontal support surface of the base 4.
Mounted in tandem with the elastic bearing 50 and interconnecting the upper plate 56 of the bearing 50 with the bottom of the transmission mounting flange leg 25 is an extensible and retractible spacing link 60. The spacing link 60 provides an adjustable span between the elastic bearing 50 and the support surface. A cylinder 38 of the spacing link 60 is mounted to the bearing 50 and a piston 40 reciprocally carried in the cylinder 38 includes an upwardly projecting piston rod 44. The distal end of the piston rod 44 is secured to the undersurface of the mounting flange leg 25.
Also depicted in FIG. 3 is a detailed schematized illustration of a servo valve 18 associated with the support unit 6. The servo valve 18 is connected to a source 24 of high pressure hydraulic fluid through a fluid line 20 which includes a suitable system filter 22. The servo valve 18 is also connected to a fluid discharge line 26 which empties into a convenient sump 28.
The piston 40 divides the cylinder 38 into an upper chamber, 32 which is connected to the servo valve 18 by a fluid line 30, and a lower cylinder chamber 36, which is connected to the servo valve 18 by a fluid line 34.
The spacing link 60 comprises a hydraulic distance compensating device for varying the span to compensate for dimensional changes of the elastic bearing 50 in a support direction indicated by a double headed arrow 42. The spacing link thus serves to maintain or stabilize the distance between the transmission 2 and the base 4 at the location of each support unit.
The distance to be stabilized is indicated by a double headed arrow 48 in each of the drawing figures. Changes in the distance 48 at each support unit 6, 12 occur due to compression or expansion of the elastic slabs 58 of the elastic bearings 50 in the support direction 42 of each support unit.
In the inactive or predetermined state of transmission operation, the distance 48 has a desired value at each respective support unit. Such value is determined by the positional relationships between the transmission and other drive system components. Vibrations in the transmission 2, torque shocks in the transmission, axial thrust and deformations of the base 4 or of the ship's hull result in variations in the actual values of the distances 48.
The spacing link 60 serves to maintain the instantaneous or measured value of the respective distances 48 relatively constant notwithstanding deformations of the elastic slabs 58. When the elastic bearing 50 is compressed in the support direction 42, the associated distance 48 is reduced and the sensors 7 transmit signals to the control unit 16 indicating the reduction of the distance 48. The control unit 16 thereafter provides an appropriate signal to the servo valve 18 which results in a corresponding lengthening of the spacer link 60 by extending the piston rod 44 upward as viewed in FIG. 3, a length corresponding to the distance which the elastic bearing 50 was compressed.
The desired movement of the piston rod 44 is provided by increasing the hydraulic pressure in the lower chamber 36 of the cylinder 38 and reducing the pressure in the upper chamber 32. In both cylinder chambers, 32, 36 the hydraulic pressure is maintained at an intensity such that the distance 48 is preserved at the desired level.
To effectuate the necessary pressure changes, the servo valve 18 is displaceable into one of three positions under appropriate signals from the control unit 16. In the position illustrated in FIG. 3, the fluid lines 30, 34 extending to the cylinder are not connected to either the feed line 20 or the discharge line 26. Thus, the piston 40 is fixedly maintained.
To effect upward movement of the piston rod 44, the servo valve is displaced downwardly, thereby interconnecting the feed line 20 with the lower chamber 36 while simultaneously interconnecting the upper chamber 32 with the discharge line 26. The piston 40 and the piston rod 44 move upward, increasing the span between the bearing and the transmission flange, raising the transmission mounting flange and the transmission and increasing the distance 48. When the sensed distance 48 corresponds to the predetermined desired value, the control unit 16 displaces the servo valve 18 upwardly to the FIG. 3 position, effectively sealing both of the piston chambers and preventing further movement of the piston rod.
If, due to torque load changes or other factors, the elastic bearing 50 expands in length in the support direction 42, the increased distance 48, as sensed by the sensors 7, causes the control unit 16 to generate a signal which displaces the servo valve 18 upwardly to connect the lower chamber 36 with the fluid discharge line 26, through the line 34 and, at the same time, connecting the upper chamber 32 to the feed line 20, through the fluid line 30. This results in increased fluid pressure in the upper chamber 32 and decreased fluid pressure in the lower chamber whereby the spacing link 60 reduces its length and decreases the span due to inward displacement of the piston rod 44. Such inward displacement of the piston rod 44 continues until the actual distance 48 has again reached the desired value after which the valve 18 is switched to the position shown in FIG. 3.
Each of the support units 6, 12 is controlled by a dedicated servo valve 18 in accordance with the circuit illustrated in FIG. 3 with a single control unit 16 generating signals to individually control each of the servo valves in response to the actual distance signals generated by each of the sensors 7, 13.
In view of the foregoing, it can be seen that the compensating transmission mount system of the present invention renders it feasible to use relatively soft yieldable bearings without the transmissions being subject to harmful displacements relative to the remaining drive system components. This provides a much more efficient and effective absorption of shocks, damping and vibration reduction attenuation than previously possible.
It should also be appreciated that although the mount system of the present invention has been described for use in conjunction with transmissions such as ship transmissions, it may find application in various other systems and components and may readily be adapted for use as motor mounts or in other systems wherein shock and vibration isolation are desired yet relative movement of system components is to be avoided.
Thus it will be seen that there is provided a compensating transmission mount system which achieves the various aspects, features and considerations of the present invention and which is well suited to meet the conditional of practical usage.
As various possible further embodiments might be made of the present invention, and as various changes might be made in the illustrative embodiment above set forth, it is to be understood that all matter herein described or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | A transmission mounting system includes a plurality of adjustable support units which are positioned between a transmission and supporting or reference surfaces. Each support unit includes a relatively yieldable elastic bearing and an extensible-retractible spacing link arranged in tandem. Signals indicative of the distance between transmission and the support surface are generated by a sensor and received by a control unit. The control unit effects dimension changes in the spacing link which compensate for deformation of the elastic bearing. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a pressure control unit for vehicular hydraulic brake systems with a braking force distributor featuring a piston arrangement prestressed by a control force into its rest position, acted upon by an outlet pressure counteracting the control force, and being movable as a result of which an outlet chamber is enlarged, the braking force distributor further featuring a normally open valve by means of which a connection is locked between an inlet and the outlet chamber as soon as the piston arrangement has moved out of its rest position against the control force.
Such a braking force distributor has come to knowledge from the German Pat. (Dt-PS) No. 1,195,185. The braking force distributor is used for balancing the braking pressures between the front and rear axles of a vehicle to which end it is interconnected in the pressure medium line between the braking pressure source and the rear axle brakes. Its fundamental mode of operation consists in that it allows full action of the pressure generated by the braking pressure source on the rear axle brakes up to a determined pressure level. When this pressure level (change point) has been reached the piston arrangement will move out of its rest position, causing the valve to close and ensuring that - as the pressure is further increasing - no further pressure (braking force limiter) or only an outlet pressure will reach the rear axle which outlet pressure is limited as compared with the inlet pressure (braking force reducer). If a limited pressure increase is to be achieved it is necessary for the piston arrangement to have another surface which can be acted upon by the inlet pressure in the direction of the control force and which is smaller than the surface acted upon by the outlet pressure in the opposite direction. The relationship of these two surfaces will determine the further pressure increase in the outlet chamber. If there is no surface acted upon by the inlet pressure there will be no further pressure increase beyond the change point, i.e. in this case the device is a braking force limiter.
Such a balancing of the braking pressures is necessary to ensure that, with various friction values, all the wheels of a vehicle will approach the lock-up limit as evenly as possible. Considering e.g. a brake system which is designed for a medium-degree braking operation without any such braking pressure balancing, a good friction value and the good braking action hence being possible will lead to a strong dynamic axle load shift as a result of which the rear wheels would already be locked before the highest braking force possible would become effective at the front wheels, while in the event of a poor friction value and of the weak braking action hence being possible conditions are completely reversed due to the small axle load shift which may then be neglected. However, even the braking pressure balancing by means of a braking force distributor cannot completely prevent the wheels from locking. All that is thereby only achieved is that the wheels of one axle are prevented from premature locking.
In order to prevent a wheel lock-up on principle, antiskid control systems have been developed which among others feature a pressure control device. Such an antiskid control system has come to knowledge from the German Printed Patent Application (Dt-AS) No. 1,530,471. The pressure control device disclosed there has a plunger which is held in its rest position by a strong spring and which is displaceable by means of a controlled auxiliary pressure against the force of the spring, thereby a control chamber being enlarged and at the same time a valve being closed which is mechanically controlled by the plunger. The valve prevents any further braking pressure supply from the pressure medium source to the control chamber while in the chamber and in the wheel brake connected therewith the braking pressure is reduced by the increase in volume of the control chamber. To this end, the auxiliary pressure is controlled such as to bring about a braking pressure which will just prevent the wheels from locking.
Up to now it was assumed that in vehicles equipped with an antiskid control system the braking pressure balancing is of minor importance since the antiskid control system provides for a better prevention of a wheel lock-up than does a braking force distributor. It was thus assumed that the braking force distributor is dispensable in such vehicles. This, however, leads to a response of the antiskid control system which is connected with the wheels of the dynamically load-relieved axle even if the optimum braking pressure has not yet been reached at the wheels of the other axle. Upon any stronger braking operation, the wheels of the dynamically load-relieved axle are thus strained up to the lock-up limit and overbraking will only be prevented by the continuous operation of the antiskid control system. This in itself is disadvantageous enough. However, if in addition one thinks of the fact that with antiskid control systems the possibility of failure has to be considered and that in such a case the brake system is to work as if no antiskid control system were provided at all, then this is a state which is intolerable. In such a case, upon the failure of the antiskid control system the wheels of the dynamically load-relieved axle will very soon be overbraked as a result of which the vehicle will normally skid since it is the rear wheels that are affected.
Thus one arrives at the conclusion that despite the installation of an antiskid control system a good braking pressure balancing is needed. The most simple way to provide such an optimum brake system is to provide both devices, i.e. an antiskid control system and a braking force distributor. In consequence, however, the entire brake system will become very voluminous and expensive.
SUMMARY OF THE INVENTION
It is thus an object of the present invention to further develop a pressure control device of the type referred to at the beginning such as to achieve that it, besides being suitable for braking pressure balancing, will simultaneously be suitable for braking pressure modulation in the sense of an antiskid control, dependent on an auxiliary pressure controlled for the purpose of antiskid control.
A feature of the present invention is the provision of an improvement in a braking pressure control unit for vehicular hydraulic brake system with a brake force distributor featuring a housing having a longitudinal axis, a piston arrangement coaxial of the axis prestressed by a control force into its rest position, acted upon by an output pressure counteracting the control force, and being movable as a result of which an output chamber is enlarged, the distributor further featuring a valve which is open in its rest position and by means of which a connection is blocked between an input and output chamber as soon as the piston arrangement has moved out of its rest position against the control force, the improvement comprising a secondary piston which is acted upon by an auxiliary pressure due to an antiskid system and which acts against the control force.
Thereby it is achieved in the most simple manner that this sole braking pressure control unit performs both the braking pressure balancing and the braking pressure modulation for antiskid control. As long as the auxiliary pressure is not applied to the secondary piston the function corresponds to that of any normal braking force distributor, irrespective of whether the auxiliary pressure is not effective since there is no danger of a lock-up, or since the antiskid control system is defective. However, as soon as the antiskid control responds the braking pressure control unit will be influenced in the sense of a braking pressure modulation by the fact that the equilibrium of forces at the piston arrangement is influenced by the secondary piston, the secondary piston reducing the control force.
It is advantageous if the secondary piston can be supported at the piston arrangement against the control force. Thereby a complete pressure reduction for antiskid control will also be possible even if the piston arrangement has a surface to which - for the purpose of a better braking pressure balancing - the inlet pressure can be applied in parallel with the control force, i.e. if the parts forming the braking force distributor are also constructed in the sense of a braking pressure reducer and not as a mere braking pressure limiter.
One embodiment featuring a particularly simple design consists in that, with regard to the piston arrangement, the secondary piston is coaxially arranged in front of the outlet chamber and is supported by a pin projecting into the outlet chamber in a sealed displaceable manner, the secondary piston being supported by the pin on a surface of the piston arrangement which surface is acted upon by the outlet pressure. An essential advantage of this embodiment is also to be seen in the fact that in vehicle types which are only partially to be equipped with antiskid control devices in the remaining vehicles only the parts of the braking pressure control unit that form the braking force distributor can be used as a mere braking force distributor. These vehicles easily allow a later addition of antiskid control systems. Further, the number of parts forming the braking force distributor is lower so that they can be manufactured on a more economic scale.
An axially rigid connection between the piston arrangement and the secondary piston is achieved by the fact that no change in the volume or the pressure is caused in the outlet chamber by the relative movement of these parts.
Often a device is expediently provided in vehicles with dual circuit brake systems by means of which device a valve passage is opened or will remain open between the inlet and outlet chambers upon failure of the second brake circuit which is not led via the braking force distributor. From the German Printed Pat. application (Dt-AS) No. 2,221,074 a brake system is known in which, in parallel with the braking force distributor, a valve is arranged which is actuable by the pressure in the second brake circuit and the valve passage of which provides for a by-pass of the braking force distributor in the event of failure of the second brake circuit. In the braking force distributor known from the German Pat. (Dt-PS) No. 1,655,444 the piston arrangement is held in its rest position by a clamping element which will be released if there is pressure in the second brake circuit. As a result of these devices the braking pressure supplied to the first brake circuit via the braking force distributor will not be reduced or limited in the event of failure of the second brake circuit.
Such a device definitely also makes sense in the inventive braking pressure control unit. However, an advantageous embodiment provides that during the application of auxiliary pressure to the secondary piston the valve passage is always closed, irrespective of the second brake circuit. It is thus achieved that even upon failure of the second brake circuit antiskid control can become effective for the wheels connected to the braking pressure control unit, these wheels thus being braked in the best way possible.
BRIEF DESCRIPTION OF THE DRAWING
Above-mentioned and other features and objects of this invention will become more apparent by reference to the following description taken in conjunction with the accompanying drawing, in which, the single FIGURE of the drawing is a cross-sectional view of the braking pressure control unit in accordance with the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In a housing 1 a cylinder bore 3 is provided in which a piston arrangement 2 is located. One end of the piston arrangement 2 projects out of the housing 1 in a sealed displaceable manner. In the cylinder bore 3 a valve element 4 is arranged in a displaceable manner which surrounds the piston arrangement 2 and which is slightly prestressed by a return spring 7 against a stationary abutment 6 in the housing. Together with a valve member 5 provided at the piston arrangement 2, the valve element 4 forms a valve including valve element 4 and valve member 5 by means of which the cylinder bore 3 can be subdivided into an inlet chamber 8 and an outlet chamber 9. The inlet chamber 8 can be connected with a pressure medium source of a vehicular brake system via an inlet 10. The outlet chamber 9 can be connected with wheel brake cylinders of the brake system via an outlet 11. Further, a control force Q schematically illustrated by an arrow 12 is acting on the piston arrangement 2 by means of which the piston arrangement is prestressed into its rest position as shown in the drawing. The control force Q e.g. may be applied by a firmly restrained spring in a known manner or dependent on the load of the vehicle.
Coaxially with regard to the cylinder bore 3, a further cylinder 15 is provided in which a secondary piston 16 is arranged in a sealed displaceable manner. Secondary piston 16 subdivides the cylinder 15 into a chamber 17 adjacent the outlet chamber 9 communicating with the atmosphere and into an opposite control chamber 18. The control chamber 18 has a connection 19 via which it can be supplied with auxiliary pressure controlled by an antiskid control system. A pin 20 is led from the chamber 17 into the outlet chamber 9 in a sealed displaceable manner. The piston arrangement 2 can be supported at the secondary piston 16 via the pin 20, the secondary piston 16 on its part being supported in its rest position by a shoulder 21 of the housing.
Thus the following mode of operation results:
During a normal braking action pressure medium is supplied to the inlet 10, at first flowing unhindered between valve element 4 and valve member 5 to the outlet 11 and then flows to the connected wheel brake cylinders. Thus in the inlet and outlet chambers 8/9 a pressure is built up which corresponds to the pressure of the pressure medium source. The pressure is applied to the piston arrangement on a cross-sectional surface d against the control force Q. As soon as this pressure overcomes the control force Q the piston arrangement -reference being made to the drawing - is displaced to the left, the valve edge 5 thus abutting the valve element 4 and hence separating the inlet chamber 8 from the outlet chamber 9.
The pressure prevailing in the inlet chamber 8 from now onwards is acting upon the piston arrangement 2 on a surface D - d to the right while the pressure prevailing in the outlet chamber 9 acts on the piston arrangement on a surface D to the left. The pressure in the inlet chamber 8 increasing, thus the valve edge 5 will always be lifted off from the valve element 4 that long until the piston arrangement 2 will have regained its balance. Thus a reduced pressure build-up is taking place in the outlet chamber 9. The pressure curve achieved in the outlet chamber 9 during the pressure reduction is the same as that obtained during the pressure build-up. The piston arrangement 2 and the valve element 4 are moved to the left, the outlet chamber 9 thus being enlarged, for the purpose of adapting the pressures between the inlet chamber 8 and the outlet chamber 9 until this object will have been achieved.
The mode of operation described so far is that of a known braking force distributor the principle of which is based on the fact of the piston arrangement's always being displaced into a balanced position in which the outlet pressure determined by the control force Q and by the inlet pressure as well as by the surfaces d, D is achieved in correspondence with the desired pressure curve. During this operation the remaining parts are kept in their rest positions since auxiliary pressure will be built up in the control chamber 18 only if the antiskid control system becomes active. As long as this is not the case, the pin 20 is acted upon by the outlet pressure in the outlet chamber 9 during the braking operation, thus keeping the secondary piston 16 in its rest position.
Upon a lock-up, however, auxiliary pressure is built up in the control chamber 18, the secondary piston thus being displaced to the left. The force transmitted by the secondary piston 16 to the piston arrangement 2 via the pin 20, in correspondence with the level of the auxiliary pressure, displaces the piston arrangement 2 to the left, the outlet chamber 9 thus being enlarged and hence the pressure in the outlet chamber 9 and in the connected wheel brake cylinders being reduced. Thus, in this case the piston arrangement 2 and the valve element 4 are used as the plunger of an antiskid control system. After the antiskid control is terminated the secondary piston 16 and the pin 20 will return into their rest positions, the normal function of a braking force distributor being again immediately available.
Even if an antiskid control system fails this function of a braking force distributor will always be available, since in that case the secondary piston will not influence the piston arrangement. No strong emergency spring or the like is required here which in the known antiskid control systems holds the plunger in its rest position.
While we have described above the principles of our invention in connection with specific apparatus it is to be clearly understood that this description is made only by way of example and not as a limitation of the scope of our invention as set forth in the objects thereof and in the accompanying claims. | There is disclosed a combination brake-force distributor and modulator valve for an antiskid system. The normal pressure controlled piston of the brake-force distributor is at the same time used as the modulator valve of the antiskid system. In order to achieve antiskid control the piston is arranged so that is is displaced by a control piston during brake pressure reduction. | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to controlling vapor compression based heating and cooling systems. More specifically, it relates to a method and an apparatus for independently controlling both temperature and humidity and having an integrated fault detection module for use with a vapor compression based heating and cooling system.
BACKGROUND OF THE INVENTION
[0002] A vapor compression cycle based refrigeration system is commonly used as an air-conditioner or a heat pump for cooling or heating an interior building space. Typically, in the operation of a fixed speed (or constant-volume) air-conditioning system, a thermostat senses and compares the room air dry-bulb temperature to a variable set-point temperature and turns on or turns off the heating and air-conditioning system. When the system is running, air passing through an evaporator coil located in an air-handler is cooled. If the air is cooled below its dew point temperature, moisture condenses on the evaporator coil and dehumidification occurs. Therefore, in a conventional thermostatic controller, room air dry-bulb temperature is used to control space dry bulb temperature. Humidity control is only a byproduct and is not actively controlled. At a partial load (low sensible load) condition with a high humidity, the system run time is low and the desired humidity level cannot be achieved.
[0003] Faulty operation of an air-conditioning system results in increased energy use and causes uncomfortable conditions. While there are different fault conditions associated with air-conditioning systems, there are two main fault conditions—airflow volume fault and incorrect refrigerant charge. If airflow is too high, room air will not be dehumidified properly. On the other hand, if air flow is too low, the room cannot be cooled properly and results in increased energy use. Also, very low air flows can freeze the indoor evaporator coils. Studies have shown that significant airflow problems exist. Seven studies that had sufficient data suggested that seventy percent of all homes had airflow twenty percent below the recommended levels. This translates into a loss of ten percent efficiency for the most common types of central air-conditioners.
[0004] Correct refrigerant charge is very important for proper operation of an air-conditioner. Refrigerant overcharging can cause flooding, slugging, and premature compressor failure. Undercharge will prevent adequate cooling. While overcharging results in slight loss in energy efficiency, undercharging can result in significant reduction in energy efficiency. Therefore, it is critical that all of the above identified problems be diagnosed and resolved to achieve energy savings.
[0005] Both indoor air temperature and relative humidity affect an occupant's comfort. In some systems, a separate dehumidification system is integrated with an air-conditioning system to control humidity and offer improved comfort. U.S. Pat. No. 5,915,473, issued to Ganesh et al., relates to an integrated humidity and temperature controller for an air-conditioning system with an integrated dehumidifier. Instead of controlling relative humidity, indoor temperature set-point can be varied to maintain comfort conditions.
[0006] U.S. Pat. No. 6,843,068, issued to Wacker, teaches a method to adjust the set-point temperature based on humidity level for maintaining comfort. It is also known to control humidity by controlling air-flow over an indoor coil. In U.S. Pat. No. 4,003,729, issued to McGrath, an air-conditioning system with improved dehumidification is proposed. In order to achieve increased dehumidification, airflow over the evaporator coil is reduced. Air flow is varied according to monitored evaporator temperature and a desired refrigerant temperature in the evaporator is maintained at a predetermined level. In U.S. Pat. No. 5,062,276, issued to Dudley, an air-conditioner with a variable speed fan and a variable speed compressor are used to improve humidity control. The fan speed is varied generally linearly with the compressor speed set as a function of cooling demand. When the humidity is more than the set-point (humidistat), the minimum compressor speed is increased, while the minimum fan speed remains the same. U.S. Pat. No. 5,303,561, issued to Bahel, relates to a microprocessor based air-conditioning control system for optimum efficiency. The fan speed is controlled based on humidity measurement, to reduce airflow when humidity is high. U.S. Pat. No. 6,070,110, issued to Shah, et al. discloses a thermostat control that includes a temperature sensor and a humidity sensor and a process to control the indoor air fan in response to indoor temperature and humidity conditions.
[0007] A simple method for detecting faults in a residential HVAC system has just two temperature sensors measuring supply and return air temperatures. The controller sends an alarm if the temperatures and the temperature difference deviate from reference values. It doesn't provide information on refrigerant charge or airflow. A hand-held fault detection and diagnostic system for field service technicians is also known. Another method related to HVAC system fault detection is a device that monitors several temperatures and the differential pressure across an air filter to detect certain faults and alerts a service contractor. Measured temperatures include outdoor air temperature, return air temperature, liquid line temperature, suction line temperature and fan motor temperature. U. S. Pat. Nos. 6,324,854 and 6,658,373, issued to Jayanth and Rossi, et al. respectively, each describe HVAC system fault detection using a hand-held computer requiring service technicians to operate.
[0008] U.S. Pat. No. 5,628,201, issued to Bahel et al., discloses an overcharge-undercharge diagnostic system for air-conditioner control. This method uses the compressor discharge temperature measured at a predetermined expansion valve setting and compares it with a reference discharge temperature. If the measured temperature is higher than the reference, the system is undercharged and if the measured temperature is lower than the reference, the system is overcharged. U.S. Pat. No. 5,381,669, also issued to Bahel, discloses a concept of integrating charge fault detection into an air-conditioner controller. U.S. Pat. No. 5,586,445, issued to Bessler, discloses a system to detect low refrigerant charge by monitoring the compressor discharge pressure and temperature. A controller receives sensor output signals and produces a low charge signal whenever a combination of a high discharge temperature and a low discharge pressure is detected.
[0009] U.S. Pat. No. 5,860,286, issued to Tulpule, discloses a refrigerant monitoring system with neural networks. First, the neural network is trained to learn the characteristics of the system. Then, the trained network timely computes refrigerant charge during a runtime mode of operation. The variance data is made available. U.S. Pat. No. 5,987,903 issued to Bathla, describes a method to detect refrigerant charge level by measuring pressure and temperature at the condenser outlet. The detection here determines actual sub cooling and compares it with a reference sub cooling to arrive at the charge condition. U.S. Pat. No. 6,981,384 issued to Dobmeier et al. describes using mid coil temperature for condenser saturation and sub-cooled liquid temperature in the liquid line to estimate refrigerant levels in a system.
[0010] This approach to the determination of refrigerant charge level is well known. Typically, refrigerant sub-cooling in the condenser is employed for determining charge level. Refrigerant sub-cooling is the difference in refrigerant saturation temperature and the refrigerant temperature at the condenser outlet, which is lower than the saturation temperature and thus is sub-cooled. Refrigerant saturation temperature is obtained from saturation pressure-temperature relationship by measuring the refrigerant pressure at the condenser outlet or the liquid line in the refrigeration cycle. The present invention does not utilize a pressure sensor but only a temperature sensor to measure the saturation temperature directly. As described above U.S. Pat. No. 6,981,384 uses saturation temperature as measured at approximately the mid coil (or loop) of the condenser, which may be a two-phase region. However, it is experimentally determined that one or two coils above the mid coil may assure two-phase region for measuring saturation temperature in the condenser. The difference in the saturation temperature and the condenser outlet temperature is the measured condenser sub-cooling. Since it is not the same as the one obtained from the measured saturation pressure, it is referred to as equivalent sub-cooling. This equivalent sub-cooling is a direct function of the refrigerant charge level in the system. Thus a fault detection module can utilize these simple inputs to determine refrigerant level in the vapor compression system.
SUMMARY OF THE INVENTION
[0011] According to the present invention, an integrated controller performs the functions of a thermostat and a humidistat with a fault detection module incorporating only temperature sensors for fault detection. The control portion of the integrated controller includes modules to control both temperature and humidity in a conditioned space to maintain comfort conditions and eliminate conditions that promote growth of mold and mildew. The controller reads the indoor air temperature and relative humidity and compares them with the temperature and relative humidity set points as set by a user to enable normal cooling mode or dehumidification mode.
[0012] In a preferred embodiment, in one dehumidification mode, where there is a multiple or variable speed fan, the fan speed is reduced from nominal speed by thirty percent or greater. Typically, indoor airflow of 400 to 450 cubic feet per minute per ton (cfm/ton) of cooling is used. In the dehumidification mode, air flow can be reduced up to 250 cfm/ton. However, precaution must be taken so that the evaporator coil does not freeze due to very low airflow, which reduces the evaporator temperature.
[0013] National standards for indoor air quality recommend an indoor relative humidity below sixty percent for comfort and health. Therefore, in a preferred embodiment of the present invention a default maximum set-point of sixty percent for relative humidity in cooling is used, which can be reprogrammed should the need arise. When a user selects a relative humidity set-point greater than sixty percent, the set-point will be forced to the default maximum relative humidity. Similarly, the preferred embodiment incorporates a default low, or minimum, relative humidity. In this case, when a user selects a relative humidity less than the default minimum, the controller will be defaulted to the minimum relative humidity, which can also be reprogrammed. In another embodiment, in a dehumidification mode, when the air-conditioning system has a multiple or variable speed compressor along with a multiple or variable speed indoor fan, the indoor airflow is reduced to its minimum while the compressor operates at a speed suitable for the sensible heat load.
[0014] In another preferred embodiment, the integrated controller can detect a low refrigerant charge condition, an over charge condition, and an airflow fault condition. The fault detection module incorporates an indoor air temperature sensor, an outdoor air temperature sensor, indoor relative humidity sensor, supply duct air temperature and return duct air temperature. In addition, this embodiment includes a pair of temperature sensors that measure the liquid refrigerant equivalent sub-cooling for an air-conditioner with a thermostatic expansion valve and the equivalent evaporator superheat for an air-conditioner with a fixed orifice type expansion device. The amount of measured sub-cooling or superheat indicates whether the air-conditioning system is under charged or over charged or normal. The integrated control module calculates the difference in measured return air temperature and supply air temperature and compares it with a pre-determined value to establish whether the system air flow is normal, low or high. When the controller encounters a refrigerant charge fault or airflow fault, fault conditions are displayed on the controller or remotely.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic of a vapor compression based air-conditioning system;
[0016] FIG. 2 is a diagram illustrating inputs and outputs of an integrated controller for an air-conditioning system with a thermostatic expansion device (TXV);
[0017] FIG. 3 is a diagram illustrating an integrated controller for an air-conditioning system with a fixed orifice expansion device;
[0018] FIG. 4 is a flowchart of an integrated controller;
[0019] FIG. 5 is a flowchart showing a fault detection module of the integrated controller for a system with a TXV expansion device; and
[0020] FIG. 6 is a flowchart of a fault detection module of the integrated controller for a system with a fixed orifice expansion device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Referring to FIG. 1 , an integrated controller 10 combines the functions of a thermostat, a humidistat and automated fault detection into one device is shown schematically in combination with a vapor compression based air-conditioning system. As shown in FIG. 1 , the vapor compression system includes a compressor 12 , for compressing a low-pressure refrigerant vapor exiting an evaporator coil 14 into a high pressure and temperature vapor. This high pressure vapor refrigerant rejects heat to outdoor ambient air 16 in a condenser 18 condensing into a liquid. An outdoor fan 20 blows ambient air 16 across the coils and fins of condenser 18 .
[0022] The liquid refrigerant temperature at the condenser outlet 22 is generally lower than the saturation temperature of the refrigerant at that location. This difference in temperature is called as condenser sub-cooling, which is a good indicator of the level of refrigerant charge within the system. In the present invention, it is preferred that a temperature sensor is placed at least one or two coils (loops) above the mid coil of the condenser to measure the refrigerant saturation temperature. Refrigerant temperature at the outlet of the condenser is also measured. The liquid refrigerant then passes through an expansion device 24 such as a thermostatic expansion valve (TXV) or a fixed orifice device and becomes a low pressure two-phase refrigerant. This refrigerant then enters the indoor evaporator coil 14 and absorbs heat from the indoor air circulated by an indoor fan 26 . Thus indoor air is cooled by the refrigerant in the vapor compression cycle. The refrigerant leaving evaporator 14 at an evaporator outlet 28 is generally at a higher temperature than that of its saturation temperature and this difference is known as evaporator superheat, which is also a good indicator of refrigerant charge level. The refrigerant vapor then enters the compressor 12 and the cycle repeats. In effect, indoor air is cooled by absorbing heat from indoor air and rejecting the heat to outdoor air in a vapor compression based air-conditioning system.
[0023] In a conventional system, a thermostat controls the air-conditioning system using dry bulb temperature alone. As shown in FIG. 2 , a thermostat 30 is one module of an integrated controller 10 . Integrated Controller 10 also includes a humidistat module 32 and a fault detection module 34 . As shown in FIG. 2 , controller 10 is microprocessor based and has sensor inputs for indoor air dry-bulb temperature 36 , indoor relative humidity 38 , outdoor air temperature 40 , supply air temperature 42 , return air temperature 44 , equivalent liquid refrigerant saturation temperature 46 , and condenser outlet temperature 48 as measured at condenser liquid outlet 22 . Outputs include control signals 50 to compressor 12 and outdoor (condenser) fan 20 , and indoor fan 26 . A fault indicator 52 such as an LED/LCD display is activated by fault detection module 34 as described herein. Fault detection module 34 incorporates rules that are predetermined ranges for refrigerant sub-cooling or superheat to detect refrigerant fault, and ranges for temperature difference between the return air temperature 44 and supply air temperature 42 for determining airflow fault. Selectable inputs 54 are indoor temperature set-point, relative humidity set-point and occupancy schedule (time of day). The embodiment shown in FIG. 2 is applicable for an air-conditioning system with a thermostatic expansion device (TXV) or a fixed orifice but is preferably used for a system with TXV. FIG. 3 , as described further below, shows an integrated controller preferably used with an expansion device 24 of the fixed orifice type, which uses evaporator saturated temperature 56 and evaporator outlet temperature 58 to evaluate refrigerant level of the system.
[0024] Referring to FIGS. 2 and 3 , indoor airflow fault is detected by measuring the supply air temperature 42 and the return air temperature 44 . Controller 10 detects a high airflow fault if the difference in return air temperature 44 and supply air temperature 42 is lower than a predetermined value and a low airflow fault if the difference is higher than a predetermined value. Since this temperature difference is a function of outdoor temperature 40 , the predetermined values are specified at a specific outdoor temperature or specified as a function of outdoor temperature.
[0025] FIG. 3 shows a controller 10 more suitable for a system with a fixed orifice in detecting a refrigerant charge fault. For a system with fixed orifice type of expansion device 24 , evaporator superheat, which is the difference between the evaporator outlet temperature 58 and the saturation temperature 56 at the evaporator outlet is used for determining the refrigerant charge level. Evaporator saturation temperature 56 is commonly obtained by measuring pressure at the service port (low side) and from the saturation pressure-temperature relationship. However, since the present invention uses only the temperature sensors, refrigerant temperature at the evaporator inlet, which corresponds to the saturation temperature 56 and refrigerant temperature at the evaporator outlet 58 are measured. The difference between these two temperatures is the evaporator superheat. The fault detection module 34 compares the measured evaporator superheat with predetermined values. If the measured superheat is greater than the predetermined value, then a low charge fault is detected. If the measured superheat is lower than the predetermined value, then an overcharge fault is detected. Refrigerant low charge fault detection can be undertaken at a specified outdoor temperature or as a function of outdoor temperature. Accordingly, fault detection module 34 may include threshold values for superheat as a function of outdoor temperature.
[0026] In a preferred embodiment the present invention incorporates temperature and humidity control with an automatic fault detection system, which has been discussed above. In addition, according to the present invention, supply air temperature 42 or evaporator temperature 56 is monitored to prevent indoor evaporator coil freezing.
[0027] The operation of controller 10 is shown in FIG. 4 . A user of the controller 10 , in combination with a vapor compression based air-conditioning system, selects a temperature set-point (Tset) and a relative humidity set-point (RHset). The controller 10 operates the air-conditioning to maintain these temperatures. However, a typical user is accustomed to adjusting only a temperature setting on a thermostat and is not accustomed to adjusting the relative humidity setting. Therefore, to prevent improper settings, operational envelope (minimum and maximum) for relative humidity are enforced by the controller 10 . Minimum indoor air temperature (Tmin), minimum indoor relative humidity (RHmin), and maximum indoor relative humidity (RHmax) are the defaults set at the factory, which can be reprogrammed with the aid of a user manual. These default settings prevent the improper operation of the air-conditioning system. When the sensed room air temperature (T) is higher than the temperature set-point (Tset), the controller 10 checks whether the relative humidity (RH) is above the relative humidity set-point (RHset). If RH is less than RHset, then the air-conditioning system operates in normal mode, i.e., normal indoor fan speed is implemented. Otherwise, the air-conditioning system is in dehumidification mode, where the indoor airflow (fan speed) is reduced such that the evaporator temperature is greater than a pre-determined value to prevent evaporator coil freezing. When the controller 10 is employed with an air-conditioning system with a TXV expansion device 24 , an evaporator temperature sensor is utilized. However, since the controller 10 utilizes a supply air temperature sensor, which can be employed to infer the evaporator temperature, additional evaporator sensor is not required. When the controller 10 is employed with a system that has a fixed orifice expansion device 24 as in FIG. 3 , it already has a temperature sensor that monitors evaporator temperature. This temperature sensor is used in controlling the fan speed to prevent evaporator coil freezing.
[0028] When the sensed air temperature is below Tset but higher than the minimum temperature (Tmin) and RH is higher than RHmax then the system is placed in dehumidification mode. Otherwise, the system is turned OFF. If the air temperature is below Tmin, the system remains turned off. When the system is turned ON in either normal cooling mode the fault detection module 34 is activated in the controller 10 . The fault detection module 34 for a system with a TXV or fixed orifice is shown in FIG. 5 . However, this module is preferred for a system with a TXV type of expansion device 24 . As shown in FIG. 5 , when the module is activated it reads the system on-time (t on) and compares with a pre-determined time (t ss), which represents the time it takes the measured variables to reach a quasi-steady state. When t on is greater than t ss, the module begins to measure and average the variables Tout, Tcond sat 1 , Tcond out, Tsup, and Tret. When the system is turned OFF, the module computes the difference in return air temperature and supply air temperature (DT), and the equivalent sub-cooling (SC) and compares with the fault detection rules to airflow faults and refrigerant charge faults. As indicated in FIG. 5 , if DT is less than the predetermined DThigh, the high airflow is detected. However, the high airflow fault could be the result of undercharge fault as well. If the undercharge fault is negative, then the high airflow fault is confirmed. Otherwise, high airflow fault and undercharge could simultaneously occur as well. When DT greater than DTlow, then the low airflow fault is detected. When the system is operating in dehumidification mode, it will be obviously operating at a lower fan speed and hence low airflow. That is why airflow fault is not diagnosed when the system is in dehumidification mode.
[0029] Again referring to FIG. 5 , when the measured SC is less than SCunder, the module detects undercharge fault and when the measured SC is greater than SCover, the module detects refrigerant overcharge. When the system completes the fault detection process and identifies faults, it reports the faults. These faults are indicated on the display of the controller 10 . Additionally, with a communicating feature, the device can communicate the report with a service contractor or the report can be accessed through the internet.
[0030] FIG. 6 , shows the fault detection module for a system with a fixed orifice expansion device 24 . The only difference from the module for a system with a TXV is that the sub-cooling measurement is replaced by the evaporator superheat, the difference between the evaporator outlet temperature and the evaporator inlet (saturation) temperature. As shown in FIG. 6 , when SH is greater than SHunder, then an undercharge fault is detected. When the SH is less than SHover, an overcharge fault is detected.
[0031] Those skilled in the art will recognize that the present invention may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, the scope of legal protection given to this invention can only be determined by studying the following claims. | An integrated controller for controlling a vapor compression based heating and cooling system. The integrated controller includes modules for independently controlling dry bulb temperature, humidity level, and incorporating a fault detection module therewith. The fault detection module being capable of detecting abnormal refrigerant levels using only temperature sensors on the condenser with thermal expansion valve or evaporator with fixed orifice type of expansion valve. | 1 |
This is a division, of application Ser. No. 13,188, filed Feb. 16, 1979.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to isolation systems and more particularly to coal fired steam electric generation plant absorber tower isolation systems.
2. Description of the Prior Art
Because of increasing environmental standards, coal fired steam electric generation plants have been required to use absorber towers for the removal of SO 2 from the flue gas. Continuous operation of the steam electric plant is very important, and the reliability and need to perform routine maintenance of the absorber towers is such that, as direct components of steam electric generation plants, they may cause an unacceptable number of plant shut-downs. Therefore, it is necessary to be able to isolate absorber towers for repair while maintaining the operation of the plant with as many absorber towers as possible in order to satisfy environmental standards. There has been some suggestion of possibly using louver dampers, guillotine dampers, or butterfly valves. Further, there is suggestion of using a diversionary gate to direct flow in one direction or another. None of these methods have proven acceptable for complete isolation such that an individual may safely perform maintenance inside an inlet duct or absorber tower. Further, shut-down and start up procedures cannot be implemented in an acceptable manner.
SUMMARY OF THE INVENTION
The present invention permits the complete isolation of an absorber tower for maintenance purposes. In spite of the isolation, the steam electric plant may continue in operation and other absorber towers may operate. Blank-off plates are used in inlet and outlet ducts to the absorber towers along with a louver damper arrangement in each duct to allow such total isolation that an individual may enter the duct for maintenance purposes. Further shut-down and start-up procedures may be implemented using the isolation system without affecting the operation of the steam electric plant. This isolation system could be used in other situations where a particular system component is desired to be isolated while the main unit remains in operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the flue gas cleaning system of a coal fired steam electric generation plant;
FIG. 2 is a view taken along the line 2--2 in FIG. 1;
FIG. 3 is a cross-sectional view showing an inlet duct and isolation system;
FIG. 4 is a top plan view of an inlet duct entrance;
FIG. 5 is a structural view of an inlet blank-off plate;
FIG. 6 is a sectional view of an inlet blank-off plate and double tadpole gasket;
FIG. 7 is a perspective view of a closure device;
FIG. 8 is a cross sectional view of a stepped inlet duct entrance;
FIG. 9 is a side view showing the outlet ducts;
FIG. 10 is an out-away view of an outlet blank-off plate and isolation system;
FIG. 11 is a structural view of an outlet blank-off plate; and
FIG. 12 is a perspective view of a locking device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a side view of the flue gas cleaning system 10 of a coal fired steam electric plant is shown. The basic elements of the flue gas cleaning system 10, relevant to this invention, are electrostatic precipitator 12, flue gas duct 14, chimney 16, and absorber towers 18. Inlet ducts 20 and outlet ducts 22 can be seen in FIG. 2.
The inlet duct isolation of an absorber tower 18 can be seen in FIG. 3. Looking into the flue gas duct 14, inlet duct supports 30a-e can be seen. Inlet duct support 30e has been added to a pre-existing duct support structure to compensate for the removal of inlet duct support 30f, shown by the phantom line.
Inlet duct 20 leads from the flue 14 to an absorber tower 18. A blank-off plate 32 is shown in the closed position, held by closure device 34. The blank-off plate 32 pivots on a shaft 36 as it is pulled closed by a winch 38 and a cable 40. Cable 40 is guided by rollers 42a and 42b through a hole 44 in the inlet duct upper wall 46. The blank-off plate 32 is pulled shut against a rest plate 48. Extra sealing may be provided by a double tadpole gasket 50, fastened to the entrance to the inlet duct, to meet the blank-off plate 32.
Also shown are double louver dampers 52 to be used for throttling gas flow. A duct vent hole 56 for access and pressure equalization is placed in wall 46. Further a deflector 58 and a door rest 60 can be seen for use when the blank-off plate 32 is in an open position. Finally, pressure equalization is achieved by the equalization device 62 which includes valves 64 and 66 and piping 68.
Looking now at FIG. 4, the flue gas duct entrance is shown from above with the blank-off plate 32 in the closed position. The deflectors 58 and the door rest 60 can be seen from above. Also the door stop 48 is located to provide a sealing surface when the blank-off plate 32 is in the closed position.
The structure of the blank-off plate 32 is shown in FIG. 5. The plate rides or pivots on a shaft 36. The blank-off plate structure is a matrix of interior horizontal channels 70, outside horizontal structural tubing 71 and vertical structural tubing 72. This matrix supports a membrane 74. The inlet blank-off plate operates in about 350° F. in an abrasive atmosphere. The gas velocity is approximately 66 feet/second and the operating pressure ranges from 10" H 2 O to 60" H 2 O. Consequently, structural steel is used for the inlet blank-off plate.
FIG. 6 shows an enlarged view of the blank-off plate 32 meeting the tadpole gasket 50. In the preferred embodiments, the two cores 80 are a non-combustible material such as asbestos and are covered by a teflon impregnated asbestos cloth 82. The double tadpole gasket 50 is then held in place against the blank-off plate facing by a steel band 84 laid down the center of the double tadpole and fastened by bolts 86.
The closure device 34 can be seen in FIG. 7. A threaded shaft 90 is supported by shaft enclosure 92 in the flue 14 wall or the outlet duct wall 116. A foot 94 is attached to the internal end of the shaft 90, and a handle 96 is located on the external portion of the threaded shaft which also serves orientation purposes. The foot 94 pulls against the blank-off plate to provide positive closure or locking. In the same fashion, the foot 94 may pull against a tab, not shown, on the top of the blank-off plate for closure. This tab may then be used as a pushing surface by the foot 94 to assist in opening the blank-off plate. A tightening nut 91 on the threaded shaft 90 is used to tighten the foot 94 against the blank-off plate, thereby compressing the tadpole gasket 82. The tightening nut may be a spinner, hex nut or other form of tightening nut. Also shown are nylon bearings 93 at the ends of the shaft enclosure 92 for interfacing between the shaft enclosure 92 and the threaded shaft 90. A gasket 95 may also be used to minimize flue gas leakage.
As the flue gas duct 14 narrows towards the chimney 16, the stepped ceiling 101 of the flue gas duct 14 may require some modification for the closing of the blank-off plate 32. (See FIG. 8). This is accomplished be adding a plate facing 100 supported by a plate stiffener 102. In this manner a surface is provided for closing the blank-off plate 32 while the closure device 34 may still be inserted above the door for holding the blank-off plate in the closed position. The gasket 50 is shown mounted on the plate facing 100.
FIG. 9 is an external view of the outlet duct leading from the absorber towers 18 to the flue gas duct 14. The outlet blank-off plates are located in the horizontal portion 116 of the outlet duct 22. When the unit is in normal operation the blank-off plates are open and the flow is back to the flue 14 through the vertical portion 118. At the junctions of the horizontal portion of the outlet duct 116 and the flue access 118 are two outlet blank-off plates. Winches 110 operating cable 112 over the rollers 114 can also be externally seen. The rollers may be sheaves. Access means have also been illustrated in the drawing.
In FIG. 10, one junction of the horizontal outlet duct 116 and the flue access 118 is shown cut away. The outlet blank-off plate 120 can be seen with cable 112 attached. The cable 112 has been led through a hole 124 in the outlet duct wall and over a roller 122. The blank-off plate 120 swings about a shaft 126. Also note the closure device 34 for the closed position. Phantom lines show the outlet blank-off plate in an open position and the lug 130 which is one portion of the latch-locking device as illustrated in FIG. 12. Also shown is one louver damper 128. The outlet blank-off plate 120 can be seen in FIG. 11. It is similar to the inlet blank-off plate 32, but is different in some respects which will be discussed. The horizontal shaft 126 is attached to a matrix of horizontal structural tubing 132 and vertical structural tubing 134. This matrix supports a membrane 136. For the outlet blank-off plate 120, the matrix swings or hangs from the shaft 126. Thus each vertical structural tubing member 134 is attached firmly to the shaft 126 while the inlet duct blank-off plate 32 has a horizontal structural tubing member supporting its matrix. Further, the outlet blank-off plate operates in a lesser temperature about 250° F. and is in a corrosive atmosphere. The outlet blank-off plate is preferably constructed of stainless steel. Also note that FIG. 10 shows a double tadpole gasket 138 attached to the outlet blank-off plate 120.
A latch-locking device 140 for the outlet blank-off plate 120 is shown in FIG. 12. A lug 130 is mounted on the blank-off plate 120 for receiving a rod 142. The rod 142 is attached to a baseplate 144 with mounting means 146 for a lever 148. Fulcrum point 150 of the lever 148 is positioned such that the rod 142 may be easily mated with the lug 130 when the outlet blank-off plate 120 is in an open position. Blank-off plate stop 143 positions lug 130 for placement of rod 142.
In operation the absorber towers are isolated from active operation by first closing the double louver dampers 52. The space between the double louver dampers can then be pressurized utilizing a seal air fan. At this point, the inlet blank-off plate is raised to closing and firmly closed by the closure device 34. Valve 64 is then closed while valve 66 is opened to release pressure in the inlet duct 120 to the atmosphere. The duct vent hole 56 may be opened to the atmosphere.
At this point the outlet louver damper 128 is closed, and the outlet blank-off plate 120 is unlocked and lowered to its closed position. A closure device 34 is used to firmly secure the door. A duct vent hole is not shown for the outlet duct but operates in the same manner as in the inlet duct to release the pressure between the door and damper to the atmosphere and open fully to the atmosphere.
If it is desired to start up the absorber towers, the man hole vents in both inlet and outlet ducts are closed. Then using the equalization device 62, valve 66 is closed and valve 64 is opened to pressurize the inlet duct. The inlet blank-off plate 32 may now be opened, and if any sealing air has been inserted between the double dampers 52 and 54 this is shut down. The double damper 52 and 54 may then be opened followed by the opening of the outlet blank-off plate 120. Finally the outlet damper 128 in the outlet duct is opened. | An absorber tower maintenance isolation system for isolating an absorber tower while maintaining a steam generation plant in operation. An inlet blank-off plate and outlet blank-off plate cooperate with louver dampers in the inlet and outlet ducts to permit shut down or start up of an absorber tower. Closure devices and locking devices act to keep the blank-off plates in position. Equalization devices and duct vent holes allow release to the atmosphere. Further, access is provided to the absorber tower inlet and outlet ducts. | 8 |
This is a continuation of application Ser. No. 08/680,511, filed Jul. 9, 1996 now U.S. Pat. No. 5,754,573, which is a continuation of application Ser. No. 08/369,465, filed Jan. 6, 1995 now U.S. Pat. No. 5,558,667, which is a continuation-in-part of Ser. No. 08/355,512, filed Dec. 14, 1994, abandoned.
TECHNICAL FIELD
The subject invention relates to a method and apparatus for treating vascular lesions. In the, subject invention, the vascular lesions are treated using a flashlamp pumped, intracavity doubled, solid state laser generating output pulses having a duration of 0.5 to 10 milliseconds.
BACKGROUND OF THE INVENTION
There has been significant interest in developing laser systems which can be used to treat various forms of vascular lesions. The type of vascular disorders that have been investigated include port wine stains, face veins, telangiectasis, and birth marks. A wide variety of medical laser systems have been proposed and introduced to treat these various disorders.
The prior art lasers were designed to generate an output wavelength which is absorbed by constituents in the blood. When the vein is irradiated, the blood is heated, causing thermal damage to the vein. The damaged vein will thrombose and collapse so that blood will no longer pass through the vein.
The most effective laser systems are designed to deliver a relatively high amount of energy in a short period of time. If the energy is delivered over too long a period, significant thermal damage will occur in regions beyond the vein being treated. In order to avoid this problem and generate higher powers in a short period of time, most prior art systems generated a pulsed output.
One common method of generating short, high energy pulses is to use a Q-switch. In a Q-switched laser, the gain medium is excited during an initial period when lasing does not occur. The Q-switch is then opened, allowing the energy stored in the gain medium to be coupled out of the resonator. Q-switched laser pulses, while having high energy, tend to be relatively short, on the order of tens of nanoseconds. One example of a Q-switched medical laser is disclosed in U.S. Pat. No. 5,217,455, issued Jun. 8, 1993 to Tan. This patent discloses a Q-switched, tunable solid state alexandrite laser which generates an output in the 600 to 1100 nanometer range. The duration of the q-switched pulses is 10 to 300 nanoseconds.
In addition to solid state lasers, tunable dye lasers have also been used for treatment of pigmented lesions. For example, U.S. Pat. No. 5,312,395, issued May 17, 1994, to Tan relates to a dye laser having an output of 345 to 600 nanometers. The patent suggests that the duration of the output pulses should be 500 nanoseconds or less.
In order to provide a wider range of treatment options, it has been suggested that medical laser systems include more than one type of laser. For example, PCT Application No. WO 91/13652, published Sep. 19, 1991, discloses a laser system where both an alexandrite laser and a dye laser are combined in one housing.
It has been recognized that it would be desirable to generate high power pulses having a duration longer than is available in prior art medical laser systems. This problem was addressed in U.S. Pat. No. 5,287,380, issued Feb. 15, 1994, to Hsia. This patent relates to a flash lamp pumped dye laser. A flashlamp power circuit is disclosed which ramps up the amplitude of the drive current in S order to increase the pulse length above 500 microseconds. By using the approach in the Hsia patent, an output pulse of 640 microseconds was created.
The inventors herein believe that the effectiveness of the treatment can be further enhanced if the pulse width can be even further lengthened. More specifically, it is believed that when pulses widths on the order of 500 microseconds or less are used, the laser energy tends to boil the blood in the veins being treated. When the blood is boiled, there is rapid expansion, bleeding and immediate purpura (bruises).
In preliminary investigations, the inventors herein have shown that improved results can be achieved with pulse widths in excess of 500 microseconds. When longer pulse widths are used, the veins tend to be coagulated without boiling the blood. As noted above, there is an upper limit on the ideal pulse width, since longer pulses result in excess thermal damage beyond the treatment site. Therefore, it is believed than an ideal system would be able to generate output pulses having a duration between 0.5 and 10 milliseconds, at a wavelength which is absorbed in the blood and having sufficient power to coagulate the vein.
Accordingly, it is an object of the subject invention to develop a laser system which can generate a long pulse output with sufficient power to coagulate and collapse veins.
SUMMARY OF THE INVENTION
This object is achieved in the subject invention wherein a laser system is provided which is capable of generating pulses exceeding 0.5 milliseconds, having a wavelength of 532 nm which is readily absorbed in the blood and having an energy of at least 0.5 joules per pulse. The laser system includes a neodymium doped solid state gain medium having a fundamental output wavelength of 1.06 microns. In accordance with the subject invention, a non-linear crystal, such as KTP, is located in the resonator at a focal point of the circulating beam. The non-linear crystal functions to double the frequency of the fundamental wavelength and generate output pulses at 532 nm.
A flashlamp is used to energize the gain medium. In accordance with the subject invention, the flashlamp pulses are arranged to generate output pulses in excess of 0.5 milliseconds and preferably between 0.5 to 10 milliseconds. The energy per pulse is on the order of 0.5 to 3.0 joules. It has been shown that pulses of this character can be used to coagulate unwanted blood vessels with a minimum of bleeding and pain.
It should be noted that intracavity, frequency doubled Nd:YAG lasers have been used in the prior art to treat vascular lesions. However, to the applicants knowledge, those systems have been operated with a Q-switch to generate very short pulses having a high peak power. It is believed that the subject long pulse, intracavity doubled Nd:YAG is the first laser of this type to be used for this purpose.
Further objects and advantages of the subject invention will become apparent from the following detailed description taken in conjunction with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic diagram of the laser system of the subject invention.
FIG. 2 is a top plan view of a preferred form of the laser system of the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is illustrated a schematic diagram of the laser 10 of the subject invention. The laser includes a neodymium doped solid state rod 20. The host crystal is preferably YAG, but could be any of the other standard hosts such as YLF and YSGG. When excited by a flashlamp 22, the Nd:YAG rod emits an output wavelength of 1.06 microns. This output is circulated within a resonant cavity bounded by highly reflective end mirrors 30 and 32.
Also included within the resonant cavity is a non-linear crystal 36. Non-linear crystal is provided to double the frequency of the fundamental wavelength generated by the Nd:YAG crystal 20. Suitable crystals for converting the 1.06 micron radiation into 532 nm light include KTP, BBO and KDP.
In the preferred embodiment, crystal 36 is located in a focusing branch of the resonator defined between curved end mirror 32 and curved mirror 40. It is desirable to focus the light within the crystal to increase the doubling efficiency.
Mirrors 30, 32 and 40 are provided with a coating which is highly reflective at both 1.06 microns and 532 nm. An output coupler mirror 44 is provided which is highly reflective at 1.06 microns and highly transmissive at 532 nm. By this arrangement, the doubling effect occurs through two passes through crystal 36. Light coupled out of the resonator through coupler 44 can be delivered to a vein 46 at the treatment site through either a fiber optic element or a hollow waveguide channel.
A control circuit 48 is provided for regulating the power supply 50. In operation, the control circuit will signal the power supply to energize the flashlamp. In the preferred embodiment, the flashlamp drive pulses have a duration between 0.5 and 10.0 milliseconds. At these pulse widths, a significant amount of intracavity power can be built up to enhance the efficiency of the doubling process.
FIG. 2 is top plan view of the lay out of the preferred form of the subject invention. The optical elements of the laser are mounted on a housing 12. A laser head 14 includes a Nd:YAG rod 20 and the flashlamp 22. The flashlamp and rod are water cooled with a circulation system in a conventional manner.
The gain medium 20 lies within the resonator defined by curved mirrors 30 and 32. The spacing of the mirrors is set to optimize performance at 1.06 microns. The non-linear crystal 36 is located within a focusing branch of the resonator defined by end mirror 32 and curved fold mirror 40. Each of these mirrors includes a coating is which highly reflective at both 1.06 microns and 532 nm. A flat output coupler 44 is provided which is highly reflective (about 98%) at 1.06 microns and highly transmissive at 532 nm.
A shutter 54 is provided in the cavity which is selectively positionable into the path of the laser beam. Upon start-up, the shutter is oriented to block the beam. During the first second or two of flashlamp operation, the gain medium 20 will become heated and any thermal lens effects will tend to stabilize. Once the thermal gradients in the gain medium have stabilized, the shutter is moved and the beam is permitted to reach the crystal 36. In this manner, the damage to the crystal from hot spots created by thermal lensing in the gain medium during warm-up is minimized. The use of the shutter also results in a more stable output.
A reflective filter 56 is mounted on the housing 12 to reject any 1.06 micron radiation which is transmitted past the output coupler. This portion of the beam is captured by a beam dump 58. The output beam is then directing into a fiber focus assembly 60 which includes an adjustable lens for injecting the laser output into a fiber.
Unlike prior art Q-switched system, which generate very short, high peak power pulses, the pulses generated by the subject system are longer and have lower peak power. For this reason, the doubling efficiency is less than with Q-switched lasers. In tests with the subject system, it is estimated that the doubling efficiency is on the order of 1 to 2 percent. Nonetheless, the subject system has been designed to generate pulses having an energy from 0.5 to 3.0 joules. At the longer pulse widths available from the subject system, high power pulses can be generated. For example, a one joule, two millisecond pulse will produce 500 watts of peak power.
The subject system has been used experimentally in animal studies. In the animal studies, albino rabbits were anesthetized by intramuscular injection of ketamine. The fur was depilated from the dorsal ear surfaces with Neet. Peripheral ear venules were selected and their diameters measured under a dissecting microscope. Marker dots were placed on either side of each venule at the site to be exposed to the laser. These assured accurate laser exposure placement and orientation for histological sectioning perpendicular to the venule.
In each animal, laser exposures were performed in duplicate for 160 and 320 μm vessels. The exposure durations were one, five and ten milliseconds. The fluences varied between 10 and 20 J/cm 2 . Each exposed vessel was observed immediately and at five and ten minutes for responses including vasodilation, vasoconstriction, apparent flow changes, closure and hemorrhage. Two to three hours after exposure, the sites were biopsied and fixed in formalin for routine processing and light microscopic histology after staining with hematoxylin/eosin stains.
Laser pulses of five to ten milliseconds at fluences between 10 and 15 J/cm 2 , caused clinically a vasoconstriction reaction in the targeted vessels. Histologically, the endothelial cells in these vessels were damaged and polymorphonuclear cells stuck to the interior vessel wall. The red blood cells showed partial or complete agglutination. The vessels were also surrounded by a fine rim of perivascular collagen denaturation. Polarized microscopy showed that the damaged collagen had also lost is birefringence. At 20 J/cm 2 , the vascular injury was similar, but there was pronounced epidermal and adjacent collagen damage. This was prevented by cooling of the skin during laser exposures with a cooling chamber.
Based on the above, it can be seen that the subject laser produces an ideal output format for treating various vascular lesions. The longer pulse width tends to significantly reduce purpura while still minimizing thermal damage to surrounding tissue.
Based on the results described above, the following general treatment parameters can be defined for use in human patients.
PULSE DURATION (Pulsewidth)
The ideal pulse duration for treating most portwine stains (PWS) and small telangiectasia is 1-10 milliseconds. This corresponds to thermal relaxation times of vessels approximately 30-100 micron diameter, typical for PWS lesions. This pulse duration therefore achieves thermal confinement on the order of the vessels, but less mechanical damage and hemorrhage than for sub-millisecond (e.g., pulsed dye laser) pulses. The 1-10 millisecond pulse duration also allows heat flow into the vessel wall during the response time, increasing effectiveness of vessel wall coagulation.
FLUENCE
The fluence needed for treatment with this laser lies between those typically used with the sub-millisecond 585 nm dye lasers (58 Joules/cm 2 ) and those typically used with longer duration exposures from argon, krypton, argon-dye, copper vapor, or KTP lasers (25-40 Joules/cm 2 ). As with dye lasers, the ideal fluence also varies inversely with the exposure spot diameter, for spots less than about 5 mm, and with skin melanin content (pigmentation). The ideal fluence is typically 12-20 Joules/cm 2 for spots of 3 mm, and somewhat higher for spots less than 3 mm, in most Caucasians.
PULSE REPETITION RATE
Exposures are produced contiguously on the skin. For manual placement, a repetition rate of up to about 10 Hz is controllable. For speed of operation, a rate of at least 1 Hz is desirable.
OVERLAPPING PULSES
One method of application practical with this laser is overlapping (multiple) pulses to a given skin site. Two modes can be used. When at least 10 seconds are allowed for bulk cooling between pulses, thermal damage can remain selective for vessels. If gross coagulation is desired, however, multiple pulses can be delivered faster, e.g., at 1-10 Hz until a grey-white color change indicating gross coagulation is seen.
While the subject invention has been described with reference to a preferred embodiment, various changes and modifications could be made therein, by one skilled in the art, without varying from the scope and spirit of the subject invention as defined by the appended claims. | An apparatus and method is disclosed for treating vascular lesions. In the preferred embodiment, an intracavity, frequency doubled Nd:YAG laser is used to generate output pulses having a duration of 0.5 to 10.0 milliseconds. This laser output is used to irradiate the lesions. The laser energy is absorbed in the blood of the vein, causing it to coagulate and collapse. The long pulse duration helps to minimize bleeding while controlling thermal damage to surrounding tissue. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to an inertia drive type starter motor for an internal combustion engine.
Inertia drive type starter motors rely on inertia of the pinion or clutch mechanism to move the pinion from a rest position to an engaged position against a spring force when the motor is switched on. Such motor drives have been used successfully but do suffer from false starts whereby the pinion is disengaged prematurely by sudden rotation of the engine being started which occurs not only when the motor starts but also when the engine misfires or fires but does not start. These false starts disengage the starter motor pinion requiring the starting sequence to be re-initiated. They can also suffer from bounce out or pump out which is a condition where the pinion oscillates along the shaft while engaging the engine ring gear and is a condition that can result in complete disengagement.
Thus a positive engagement mechanism for an inertia drive is desirable. Two such type drives are shown in U.S. Pat. No. 2,923,162 and U.S. Pat. No. 4,502,429. U.S. Pat. No. 4,502,429 shows a device which is very complex while U.S. Pat. No. 2,923,162 shows a device wherein the inertia drive is not assisted by the holding mechanism.
SUMMARY OF THE INVENTION
According to one aspect thereof, the present invention provides an electric starter for an internal combustion engine comprising: an electric motor having a housing and a rotatable armature shaft extending therethrough, the shaft having a helical spline portion; a pinion gear mounted for selectively engaging a ring gear of the engine; a clutch assembly for transmitting torque between the shaft and the pinion gear, the clutch assembly having a driving part and a driven part, the driving part having an internal helical spline portion engaging the helical spline portion of the shaft whereby relative rotary movement between the shaft and the driving part creates axial movement of the clutch assembly along the shaft, and the pinion gear being fixed for rotation with the driven part; and a solenoid for holding the pinion gear in engagement with the ring gear wherein the solenoid has a toroidal coil and a tubular plunger located about the shaft between the motor housing and clutch assembly, the tubular plunger having a radially extending flange at a first end which is arranged to be attracted to the radial housing wall toward the coil.
According to a second aspect, the present invention provides a solenoid comprising a housing; a cap fitted to the housing and defining an internal void, the housing and the cap each having a through hole defining therebetween a through passage having an axis; a toroidal coil fitted to the housing about the through passage; a bearing fitted to the through hole in the housing and having a through hole aligned coaxially with the through passage; and a plunger having a tubular body extending axially along the through passage and slidably retained in the through hole of the bearing, the plunger having a radially extending flange at a first end of the tubular body.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment will now be described by way of example only with reference to the accompanying drawings, in which:
FIG. 1 depicts a starter motor according to a preferred embodiment of the present invention;
FIG. 2 is a sectional view of the motor of FIG. 1;
FIG. 3 is an enlarged sectional view of a drive mechanism of FIG. 2;
FIG. 4 is a view similar to FIG. 3 with the drive mechanism in an alternate engaged position; and
FIG. 5 is an exploded view of a solenoid forming a part of the drive mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a starter for an internal combustion engine. The starter comprises an electric motor 12 having a driving shaft 14 , and a pinion mechanism. The pinion mechanism has a solenoid 34 that is mounted on an end plate 22 of the motor and a pinion 48 that is movable along the shaft 14 .
FIG. 2 is a longitudinal sectional view of the starter of FIG. 1 . The motor 12 is of the DC permanent magnet type. The motor 12 has a housing 18 supporting permanent magnets 20 . End plates 22 support bearings 24 in which the motor shaft 14 is journaled. The shaft supports a wound armature 26 and a commutator 28 fed by four conducting brushes 30 . Two brushes are connected to the single motor terminal 32 and the other two are connected to the housing 18 which acts as a ground terminal.
On the output end of the shaft 14 , outside the motor housing, is the pinion mechanism which is more clearly shown in FIGS. 3 and 4. The pinion mechanism comprises the pinion 48 , an overrunning clutch 40 and the solenoid 34 . The pinion 48 is moveable along the shaft 14 between a disengaged position as shown in FIG. 3 and an engaged position as shown in FIG. 4 . In the engaged position, the pinion engages the teeth of a ring gear for starting an internal combustion engine (not shown).
Disposed between the pinion 48 and the solenoid 34 is an overrunning clutch, ORC 40 , which is fitted to a helical spline 42 on the shaft 14 . The ORC has a driving part 44 which engages the spline 42 and a driven part 46 which is integral with the pinion 48 . The driving part and the driven part are connected together by a one way clutch mechanism 50 which allows the driven part 46 to turn with respect to the driving part 44 in one direction only.
The solenoid 34 is shown in exploded form in FIG. 5 . The solenoid 34 has a cap 60 , a plunger 38 , a coil 36 , a bearing 66 and a housing 68 . The housing 68 accommodates the coil 36 and has a slot 70 for a lead wire 72 of the coil. Lead wire 72 is directly connected to the motor terminal ( 32 , FIG. 2) so that the solenoid is energized with the motor. A rubber grommet 74 guides the lead wire 72 through the slot 70 and also seals the slot 72 against water and dust ingress. The other end of the coil (not shown) is soldered directly to the solenoid housing. The coil 36 is located about the bearing 66 and may be pressed onto the bearing 66 for support. One end of the bearing 66 is fitted to an axial hole passing through the solenoid housing 68 . The other end of the bearing 66 has a flange for supporting the coil 36 against axial movement. The plunger 38 has an axially extending tube portion 76 which slides in the bearing 66 and locates about the shaft 14 . A flange portion 78 extends radially from one end of the tube portion 76 . The cap 60 covers the space about the plunger 38 between the housing 68 and the end plate 22 of the motor. The cap is crimped over the housing to seal the solenoid. The solenoid is fixed to the motor by two screws passing through motor end plate 22 and screwed into the cover 60 .
When the solenoid is actuated, the magnetic field attracts the flange portion 78 to the radial wall of housing 68 toward coil 36 . in the disengaged position, the force on the plunger may not be very strong but in the engage position, the flange 78 is adjacent the coil 36 and is held very strongly which is where the strength is needed. The plunger butts against the driving part 44 of the ORC allowing the ORC to rotate about the shaft with respect to the plunger. Alternatively, the plunger could be coupled or fixed to the ORC so that the plunger does rotate with the ORC, if desired.
Returning to FIGS. 3 and 4, a nut 52 is threaded onto the end of the shaft 14 . An anti-drift spring 54 extends between the pinion 48 and the nut 52 to bias the pinion 48 into the disengaged position. A washer 56 is provided between the spring 54 and the nut 52 to provide a seat for the spring 54 . At the other end of the spring, a sleeve or spacer 58 forms a seat and retainer for the spring 54 allowing the pinion 48 to rotate about the shaft 14 while compressing the spring 54 axially without significant torsional stress which may otherwise cause the spring 54 to bind on the shaft 14 or to become unwound affecting its spring properties.
When the motor 12 is turned on, the shaft 14 starts to rotate. Due to the inertia of the ORC 40 , it does not rotate initially as fast as the shaft 14 and is thus moved axially to the right by the helical splines 42 as the shaft 14 turns relative to the ORC 40 , against the urgings of the anti-drift spring 54 . At the end of travel, the ORC 40 has moved towards the end of the shaft 14 to the engaged position, as shown in FIG. 4, where the pinion 48 is, in use, engaged with teeth of a ring gear fitted to a flywheel of the engine being started (not shown). The anti-drift spring 54 is now compressed. As the motor is switched on, power is also supplied to the solenoid 34 , causing the plunger 38 to move to the right, axially with respect to the shaft, pressing against the ORC 40 , helping the inertia movement and resisting pump out or disengagement of the pinion 48 from the ring gear, thereby providing positive retention of the pinion 48 in the engaged position until the power to the starter is switched off.
Once the power is switched off, the solenoid 34 releases the plunger 38 allowing the ORC 40 to return to the disengaged position. Assuming that the engine has started at this time, then the pinion 48 which is engaged with the ring gear will be rotating faster than the motor shaft because of the ORC 40 . The ORC can now move axially under the influence of the anti-drift spring 54 by rotating about the shaft 14 on the helical splines 42 .
If the engine has not started, once the starter motor has stopped rotating, the pinion 48 will slide freely out of engagement with the ring gear under the influence of the anti-drift spring 54 . Thus the ORC 40 and pinion 48 return to the disengaged position, ready to try again.
While only the preferred embodiment has been described, various modifications will be apparent to persons skilled in the art and it is intended that all such modifications and variations form part of the invention as defined by the appended claims. | A starter motor for an internal combustion engine has an inertia type pinion mechanism and an axial solenoid 34 which is arranged to prevent pump out of the pinion 48 during start up of the engine. | 8 |
BACKGROUND
[0001] Viscous hydrocarbon recovery is a segment of the overall hydrocarbon recovery industry that is increasingly important from the standpoint of global hydrocarbon reserves and associated product cost. In view hereof, there is increasing pressure to develop new technologies capable of producing viscous reserves economically and efficiently. Steam Assisted Gravity Drainage (SAGD) is one technology that is being used and explored with good results in some wellbore systems. Other wellbore systems however where there is a significant horizontal or near horizontal length of the wellbore system present profile challenges both for heat distribution and for production. In some cases, similar issues arise even in vertical systems.
[0002] Both inflow and outflow profiles (e.g. production and stimulation) are desired to be as uniform as possible relative to the particular borehole. This should enhance efficiency as well as avoid early water breakthrough. Breakthrough is clearly inefficient as hydrocarbon material is likely to be left in situ rather than being produced. Profiles are important in all well types but it will be understood that the more viscous the target material the greater the difficulty in maintaining a uniform profile.
[0003] Another issue in conjunction with SAGD systems is that the heat of steam injected to facilitate hydrocarbon recovery is sufficient to damage downhole components due to thermal expansion of the components. This can increase expenses to operators and reduce recovery of target fluids. Since viscous hydrocarbon reserves are likely to become only more important as other resources become depleted, configurations and methods that improve recovery of viscous hydrocarbons from earth formations will continue to be well received by the art.
SUMMARY
[0004] A thermally assisted downhole system including a tubular configured to be disposed within an open hole borehole, the tubular being intended to be exposed to a heated fluid; and a plurality of open hole anchors spaced along the tubular and engagable with the open hole, the anchors restricting longitudinal thermal growth of the tubular when engaged with the open hole.
[0005] A thermally assisted downhole system including a tubular within an open hole borehole, the tubular being exposed to a heated fluid; and a plurality of open hole anchors spaced along the tubular and engaged with the open hole, the anchors restricting longitudinal thermal growth of the tubular.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Referring now to the drawings wherein like elements are numbered alike in the several figures:
[0007] FIG. 1 is a schematic view of a wellbore system in a viscous hydrocarbon reservoir;
[0008] FIG. 2 is a chart illustrating a change in fluid profile over a length of the borehole with and without permeability control.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , the reader will recognize a schematic illustration of a portion of a SAGD wellbore system 10 configured with a pair of boreholes 12 and 14 . Generally, borehole 12 is the steam injection borehole and borehole 14 is the hydrocarbon recovery borehole but the disclosure should not be understood as limiting the possibilities to such. The discussion herein however will address the boreholes as illustrated. Steam injected in borehole 12 heats the surrounding formation 16 thereby reducing the viscosity of the stored hydrocarbons and facilitating gravity drainage of those hydrocarbons. Horizontal or other highly deviated well structures like those depicted tend to have greater fluid movement into and to of the formation at a heel 18 of the borehole than at a toe 20 of the borehole due simply to fluid dynamics. An issue associated with this property is that the toe 20 will suffer reduced steam application from that desired while heel 18 will experience more steam application than that desired, for example. The change in the rate of fluid movement is relatively linear (declining flow) when querying the system at intervals with increasing distance from the heel 18 toward the toe 20 . The same is true for production fluid movement whereby the heel 28 of the production borehole 14 will pass more of the target hydrocarbon fluid than the toe 30 of the production borehole 14 . This is due primarily to permeability versus pressure drop along the length of the borehole 12 or 14 . The system 10 as illustrated alleviates this issue as well as others noted above.
[0010] According to the teaching herein, one or more of the boreholes (represented by just two boreholes 12 and 14 for simplicity in illustration) is configured with one or more permeability control devices 32 that are each configured differently with respect to permeability or pressure drop in flow direction in or out of the tubular. The devices 32 nearest the heel 18 or 28 will have the least permeability while permeability will increase in each device 32 sequentially toward the toe 20 and 30 . The permeability of the device 32 closest to toe 20 or 30 will be the greatest. This will tend to balance outflow of injected fluid and inflow of production fluid over the length of the borehole 12 and 14 because the natural pressure drop of the system is opposite that created by the configuration of permeability devices as described. Permeability and/or pressure drop devices 32 usable in this configuration include inflow control devices such as product family number H48688 commercially available from Baker Oil Tools, Houston Tex., beaded matrix flow control configurations such as those disclosed in U.S. Ser. Nos. 61/052,919, 11/875,584 and 12/144,730, 12/144,406 and 12/171,707 the disclosures of which are incorporated herein by reference, or other similar devices. Adjustment of pressure drop across individual permeability devices is possible in accordance with the teaching hereof such that the desired permeability over the length of the borehole 12 or 14 as described herein is achievable. Referring to FIG. 2 , a chart of the flow of fluid over the length of borehole 12 is shown without permeability control and with permeability control. The representation is stark with regard to the profile improvement with permeability control.
[0011] In order to determine the appropriate amount of permeability for particular sections of the borehole 12 or 14 , one needs to determine the pressure in the formation over the length of the horizontal borehole. Formation pressure can be determined/measured in a number of known ways. Pressure at the heel of the borehole and pressure at the toe should also be determined/measured. This can be determined in known ways. Once both formation pressure and pressures at locations within the borehole have been ascertained, the change in pressure (ΔP) across the completion can be determined for each location where pressure within the completion has been or is tested. Mathematically this is expressed as ΔP location=P formation−P location where the locations may be the heel, the toe or any other point of interest.
[0012] A flow profile whether into or out of the completion is dictated by the ΔP at each location and the pressure inside the completion is dictated by the head of pressure associated with the column of fluid extending to the surface. The longer the column, the higher the pressure. It follows, then, that greater resistance to inflow will occur at the toe of the borehole than at the heel of the completion. In accordance with the teaching hereof permeability control is distributed such that pressure drop at a toe of the borehole is in the range of about 25% to less than 1% whereas pressure drop at the heel of the borehole is about 30% or more. In one embodiment the pressure drop at the heel is less than 45% and at the toe less than about 25%. Permeability control devices distributed between the heel and the toe will in some embodiments have individual pressure drop values between the percentage pressure drop at the toe and the percentage pressure drop at the heel. Moreover, in some embodiments the distribution of pressure drops among the permeability devices is linear while in other embodiments the distribution may follow a curve or may be discontinuous to promote inflow of fluid from areas of the formation having larger volumes of desirable liberatable fluid and reduced inflow of fluid from areas of the formation having smaller volumes of desirable liberatable fluid.
[0013] Referring back to FIG. 1 , a tubing string 40 and 50 are illustrated in boreholes 12 and 14 respectively. Open hole anchors 42 , such as Baker Oil Tools WBAnchor™ may be employed in the borehole to anchor the tubing 40 . This is helpful in that the tubing 40 experiences a significant change in thermal load and hence a significant amount of thermal expansion during well operations. Unchecked, the thermal expansion can cause damage to other downhole structures or to the tubing string 40 itself thereby affecting efficiency and production of the well system. In order to overcome this problem, one or more open hole anchors 42 are used to ensure that the tubing string 40 is restrained from excessive movement. Because the total length of mobile tubing string is reduced by the interposition of open hole anchor(s) 42 , excess extension cannot occur. In one embodiment, three open hole anchors 42 , as illustrated, are employed and are spaced by about 90 to 120 ft from one another but could in some particular applications be positioned more closely and even every 30 feet (at each pipe joint). The spacing interval is also applicable to longer runs with each open hole anchor being spaced about 90-120 ft from the next. Moreover, the exact spacing amount between anchors is not limited to that noted in this illustrated embodiment but rather can be any distance that will have the desired effect of reducing thermal expansion related wellbore damage. In addition the spacing can be even or uneven as desired. The determination of distance between anchors must take into account. The anchor length, pattern, or the number of anchor points per foot in order to adjust the anchoring effect to optimize performance based on formation type and formation strength tubular dimensions and material.
[0014] Finally in one embodiment, the tubing string 40 , 50 or both is configured with one or more baffles 60 . Baffles 60 are effective in both deterring loss of steam to formation cracks such as that illustrated in FIG. 1 as numeral 62 and in causing produced fluid to migrate through the intended permeability device 32 . More specifically, and taking the functions one at a time, the injector borehole, such as 12 , is provided with one or more baffles 60 . The baffles may be of any material having the ability to withstand the temperature at which the particular steam is injected into the formation. In one embodiment, a metal deformable seal such as one commercially known as a z-seal and available from Baker Oil Tools, Houston Tex., may be employed. And while metal deformable seals are normally intended to create a high pressure high temperature seal against a metal casing within which the seal is deployed, for the purposes taught in this disclosure, it is not necessary for the metal deformable seal to create an actual seal. That stated however, there is also no prohibition to the creation of a seal but rather then focus is upon the ability of the configuration to direct steam flow with relatively minimal leakage. In the event that an actual seal is created with the open hole formation, the intent to minimize leakage will of course be met. In the event that a seal is not created but substantially all of the steam applied to a particular region of the wellbore is delivered to that portion of the formation then the baffle will have done its job and achieved this portion of the intent of this disclosure. With respect to production, the baffles are also of use in that the drawdown of individual portions of the well can be balanced better with the baffles so that fluids from a particular area are delivered to the borehole in that area and fluids from other areas do not migrate in the annulus to the same section of the borehole but rather will enter at their respective locations. This ensures that profile control is maintained and also that where breakthrough does occur, a particular section of the borehole can be bridged and the rest will still produce target fluid as opposed to breakthrough fluid since annular flow will be inhibited by the baffles. In one embodiment baffles are placed about 100 ft or 3 liner joints apart but as noted with respect to the open hole anchors, this distance is not fixed but may be varied to fit the particular needs of the well at issue. The distance between baffles may be even or may be uneven and in some cases the baffles will be distributed as dictated by formation condition such that for example cracks in the formation will be taken into account so that a baffle will be positioned on each side of the crack when considered along the length of the tubular.
[0015] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A thermally assisted downhole system including a tubular configured to be disposed within an open hole borehole, the tubular being intended to be exposed to a heated fluid; a plurality of open hole anchors spaced along the tubular and engagable with the open hole, the anchors restricting longitudinal thermal growth of the tubular when engaged with the open hole. | 4 |
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