description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
The present invention relates to the field of electrical connectors and more particularly to double row connectors for transmission cable.
BACKGROUND OF THE INVENTION
Double row receptacle connectors are known for flat transmission cable, which comprise a connector assembly for mating with a two-row pin array. Such connector assemblies route adjacent closely spaced signal conductors of the flat cable to terminals on alternating sides of the connector while routing the respective ground conductors to a ground bus contained in the connector.
U.S. Pat. No. 4,260,209 discloses such a connector for providing solderless mass termination of a flat transmission cable, where the receptacle terminals for the signal conductors have slotted beam termination sections and are terminated to the conductors by insulation displacement. Similarly the ground conductors are secured in slotted beams of the ground bus. The receptacle terminals and ground bus are disposed along respective recesses of a housing, the conductors of the cable are terminated thereto, a cover is placed over the terminations, and a strain relief member is secured to the assembly. The connector provides for selective programming of ground terminals by connecting selected receptacle terminals to the ground bus by grounding bars or by sacrificed signal conductors.
Transmission cable having small diameter conductor wire such as 0.013 inches or less has become the cable of choice for high speed signal transmission, whether it be multi-conductor flat ribbon cable or single conductor discrete cable. Although conventional slotted beam termination works well for conductor wire of larger diameter, it has proven to be difficult to obtain reliability with very small diameter conductors. In slot terminations, the electrical connection results from a gas tight interface between the slot beams and the wire because of spring force of the beams compressing the wire, and the ability of the wire to resist compression instead of flowing. With small wires, slot tolerance allowances must be very small which is practically very difficult to maintain. The forces in the compressed wires are also very small and so is the area of contact between the beams and the wire. There is considerable risk of nicking the wire. Handling and in-service mechanical vibration can disturb the termination joint. A further result of slotted beam termination is that the tines project upwardly beyond the wire, and the wire end must project beyond the slot, both of which result in increased crosstalk and reflection, or noise.
It is desired to provide a programmable double row connector for transmission cable having small diameter wires reliably and assuredly terminated to terminals.
It is further desired to provide a termination having a large area of connection, and one whose quality can be determined upon visual inspection.
It is also desired to provide a termination for small wires which will not deteriorate during handling and vibration.
It is even further desired to reduce and make more uniform the termination resistance of the terminated wires and to minimize crosstalk and reflection in the termination area.
And it is desirable to provide a termination means and a connector adapted thereto which can be incorporated into automated cable harness assembly.
SUMMARY OF THE INVENTION
The present invention is a double row receptacle connector for high speed signal transmission cable such as flat cable, for mating with a pin array, and is suitable for automated cable harness assembly. The connector includes a premolded forward housing member having two rows of terminal-receiving passageways extending rearwardly from a mating face thereof. Box-like receptacle terminals are disposed in the passageways, having contact sections at forward ends thereof and conductor-connecting sections at rearward ends thereof. A unique ground bus is disposed in the rearward end of the forward housing parallel to the two rows of terminals and has a profiled conductor-receiving surface with conductor-receiving recesses selectively spaced therealong. The unique conductor-connecting sections of the terminals comprise slots formed by spaced walls to receive respective conductors therealong in interference fit, and adapted not to damage the conductor wires. Together the conductor-receiving slots of the terminals and the conductor-receiving surface of the ground bus define a transverse termination plane wherein stripped end portions of the respective signal and associated ground conductors of the flat cable are disposed for right angle termination. Once disposed in the respective conductor-receiving slots the conductors are laser welded to form the terminations.
A dielectric spacer is latched to the forward housing rearwardly of the plane of termination which secures the ground bus, protects the terminations and provides a cable strain relief with the insulation jacket of the cable in clamping cooperation with the forward housing. The insulated cable extends outwardly from one side of the subassembly thus formed and is bent around a selected radius for 180° and doubles back over the rearward surface of the spacer to finally extend from the other side of the connector. A dielectric cable retainer is then latchingly secured to the subassembly over the cable to complete the connector assembly and provide substantial cable strain relief by clampingly securing the cable between the cover and the spacer.
The terminals are arranged in pairs in the two rows, but the conductor-receiving slots of terminals in one row are located at a side of the passageways opposed from that side at which are located the conductor-receiving slots of the terminals of the other row. Thus, the signal conductors terminated to those of the relatively far row extend past the conductor-receiving slots of the terminals of the near row laterally spaced therefrom. The ground conductors extend past the slots of both rows of terminals spaced laterally therefrom to reach grooves in the ground bus. The ground bus may be a profiled square wire which is electrically connected to selected receptacle terminals such as by sacrificed signal conductors of the cable which are not severed just past the termination thereof with a respective terminal but extend instead to the ground bus to be terminated thereto as well. In this manner the conductor is selectively programed, providing ground terminals at any desired locations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the assembled connector of the invention.
FIG. 2 is an exploded view of part of the connector.
FIG. 3 is a longitudinal section view of the connector taken along lines 3--3 of FIG. 1.
FIG. 4 is a perspective view of a pair of terminals showing their opposed angular orientation.
FIG. 4A is a part section view of the forward end of a terminal.
FIGS. 5 and 6 are perspective views of part of the terminal assembly with a prepared cable end portion exploded therefrom and in engagement therewith for termination, respectively.
FIGS. 7 and 8 illustrate the fitting of a signal conductor into a terminal slot to be terminated.
FIG. 9 is a top view of the terminal subassembly with signal and ground conductors laser welded to respective signal terminals and the ground bus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The conductor assembly 10 is shown in FIG. 1, having a dielectric housing member 20, a dielectric spacer 102, and a dielectric cable retainer 114, all premolded of sturdy thermoplastic resin such as polyetherimide. Flat transmission cable 12 first extends outwardly from one side of connector 10, then bends around a 180° turn and extends through connector 10 to finally extend at a right angle from the other side, secured to connector 10 by retainer 114 latched by latch posts 116 to latching flanges 52 of housing 20.
In FIG. 2 housing 20 has two rows A, B of paired terminal-receiving passageways 22A,22B spaced therealong defined by parallel outer walls 24,26, a central inner wall 28, and spaced crossing walls 30, and extending from a mating face 32 to a rearward termination face 34. A respective receptacle terminal 60A,60B is secured into each passageway 22A,22B. Lead-ins are provided at the rearward ends of passageways 22A,22B to assist in automated insertion of respective terminals 60A,60B thereinto, and the forward ends of passageways 22A,22B are also preferably formed with lead-ins to receive posts or pins thereinto during mating. Along the inside of outer wall 26 is a bus-receiving channel 36 defined by aligned recesses 38 in the crossing walls 30 and a ledge 40 along outer wall 26, more clearly shown in FIG. 3. Ground bus 94 is disposed along channel 36. Cable 12 is prepared for termination and placed along termination face 34 for termination. After termination, spacer 102 is secured thereover by being latched by latching arms 106 to housing 20. When cable 12 is then bent over the top surface of spacer 102, retainer 114 is then latchingly secured to housing 20 to complete the assembly.
Flat transmission cable 12 conventionally comprises a plurality of signal conductors 14 on either side of each of which is disposed a ground conductor 16 spaced a selected distance therefrom. A thick flat insulative jacket 18 embeds all the conductors 14,16 therein by typically being extruded thereover. An end portion of cable 12 is prepared by slitting jacket 18 such as by use of a conventional CO 2 laser and sliding the severed jacket portion forwardly exposing the signal and ground conductors 14,16.
Receptacle terminals 60A,60B are identical to each other but are oriented in angular opposition when secured in respective passageways 22A,22B. Referring to FIGS. 3, 4 and 4A, each terminal 60A,60B is stamped and formed preferably from a sheet of phosphor bronze plated with gold over nickel, into a box-like receptacle body 62. A spring contact arm 64 extends forwardly in cantilever fashion from one wall of rearward body portion 66 angling inwardly to a contact section 68 proximate the forward end 70 of body 62, and curving arcuately outward to form a lead-in for receipt of a pin of a pin array (not shown) during mating. On sidewall 72 opposed from contact section 68 of spring contact arm 64, is formed an arcuate inward projection comprising a cooperating contact section 74. An assist spring 76 extends behind spring contact arm 64 as a tab from a lateral edge of an adjacent sidewall of receptacle body 62 proximate forward end 70. At the rearward end of rearward body portion 66 is a transverse tab 78 extending inwardly from one side wall to form a pin stop. Preferably one side wall of receptacle body 62 contains a lance 80 extending at a slight angle outwardly and rearwardly such that lance 80 engages a sidewall of the respective passageway 22A,22B under spring tension to assist in holding the terminal in the passageway prior to completed assembly of connector 10.
Each terminal 60A,60B has a conductor-connecting section 82 extending rearwardly from rearward body portion 66 comprising a planar first plate 84 integral with receptacle body 62, a planar second plate 86 parallel to first plate 84, and a bight 88 joined to lateral edges of both first plate 84 and second plate 86. Second plate 86 is spaced from first plate 84 a distance selected to be just less than the diameter of a signal conductor 14 of cable 12 forming a conductor-receiving slot 90. Rearward edges 92 of first plate 84 and second plate 86 are coined or swaged, forming a bevel along slot 90 to provide a lead-in along slot 90 so that a signal conductor 14 may be wiped thereinto to be held in interference fit between smooth facing surfaces of first plate 84 and second plate 86 near the top of slot 90 (as seen in FIGS. 7 and 8) without sharp edges extending into the slot which could damage the small diameter conductor wire. Second plate 86 can be urged away from first plate 84 by conductor 14, by reason of bight 88 having spring characteristics. Bight 88 does not extend to rearward edges 92 but is spaced therefrom, which permits a conductor 14 in slot 90 to extend past bight 88 into slot 90 of a terminal 60B, or to extend past conductor-connecting section 82 of a terminal 60A to ground bus 94, if desired, such as conductor 14G as seen in FIG. 9.
All the terminals in one row are of the same angular orientation, while all the terminals in the other row are of the opposite angular orientation. In this way all slots 90 of terminals 60A in row A are disposed along a common side of respective passageways 22A, while all slots 90 of terminals 60B in row B are disposed along a common opposite side of respective passageways 22B, the importance of which will soon become apparent.
In FIG. 5, ground bus 94 has a profiled termination surface 96 extending rearwardly from the termination face 34 of housing 20. Profiled surface 96 has a plurality of spaced grooves 98 thereacross of selected widths capable of receiving in interference fit single or paired ground conductors 16 of cable 12 and each signal conductor 14, if desired and having a depth about equal to the diameter of a conductor wire. Ground bus 94 can be a wire of rectangular cross-section as shown in FIG. 3, of preferably copper nickel alloy, and grooves 98 can be formed therein by precision grinding or preferably by broaching.
Lateral ends 58 are preferably tapered to assist in automated insertion of ground bus 94 into bus-receiving channel 36. Because channel 36 is preferred to be larger than ground bus 94 for insertion purposes, the precise aligning of grooves 98 is accomplished by centering ground bus 94 laterally through the use of small-dimensioned deformable vertical ribs 56 at each end of channel 36 of housing 20. During insertion as tapered ends 58 begin to engage ribs 56, the small-dimensioned ribs 56 are deformed by ground bus 94 and thus provide an interference fit which takes up tolerance.
Central wall 28 of housing 20 has a plurality of channels 44 formed thereacross corresponding to locations of all the signal and ground conductors 14,16 of cable 12, and having a width capable of receiving therein the respective signal conductors 14 or respective ones or pairs of ground conductors 16 as appropriate. Ones of channels 44 for single conductors may be V-shaped grooves 46. Crossing walls 30 are disposed at a level below channels 44. Channels 44 and V-shaped grooves 46 of central wall 28 are thus in alignment with grooves 98 of ground bus 94. V-shaped grooves 46, it can be seen, are also aligned with adjacent conductor-receiving slots 90 of respective ones of terminals 60A,60B.
With reference to FIGS. 5 and 6, the prepared cable end is to be placed atop the terminal subassembly 100 with the end portion of the cable jacket 18 adjacent cable-receiving recess 42 of outer wall 24, termed hereinafter the near wall 24, and proximate the near row A of terminals 60A. Outer wall 26 is thus the far wall 26 and the second row of terminals 60B is the far row B. The signal and ground conductors are first selectively severed.
Signal conductors 14 to be terminated to those terminals 60A in the near row A which are desired to be signal terminal locations, are severed to a length just enough to extend through respective conductor-receiving slots 90. Signal conductors 14 to be terminated to those terminals 60B in the far row B which are desired to be signal terminal locations, are similarly severed to a length just enough to extend through respective slots 90. Ground conductors 16 are all of a length appropriate to extend to ground bus 94 to be received in grooves 98 thereof for termination.
An important feature of the present invention is that the conductor-receiving slots 90 of terminals 60A,60B, the conductor-receiving grooves 98 of the ground bus 94, and the channels 44 and V-shaped grooves 46 across central wall 28, all be disposed in a common plane, or plane of termination along termination face 34 of housing 20. In this way the signal conductors 14 remain substantially undeformed by remaining unbent and in the same plane as the ground conductors 16 to assist in impedance control.
FIG. 6 shows signal conductors 14 disposed in respective slots 90 for termination, and ground conductors 16 disposed in respective grooves 98 of ground bus 94 for termination. In FIGS. 7 and 8, signal conductors 14 have been carefully wiped into respective slots 90 to be held in interference fit therein near the top of the slots. The terminal subassembly 100 thus formed is ready for the signal and ground conductors 14,16 to be laser welded to terminals 60A,60B and ground bus 94 respectively for termination. FIG. 9 shows terminal subassembly 100 after the laser welding termination process has been performed.
The ground bus 94 is electrically connected to one or more of terminals 60A,60B selected to be ground terminals by being terminated to an appropriate one or more sacrificed signal conductors 14G, as seen in FIGS. 5, 6 and 9. Such a sacrificed signal conductor 14G is severed to the same length as the ground conductors and is terminated both to the ground bus 94 and its respective receptacle terminal 60A,60B.
Following termination, as seen in FIGS. 1 and 2, spacer 102 is secured on top of the terminated subassembly 100 and against the profiled surface 96 of ground bus 94. The bottom surface of spacer 102 is disposed against the top surfaces of central wall 28 providing substantial electrical isolation between terminations of adjacent signal conductors 14. Spacer 102 has a rib 104 extending along the far side of housing 20 and held firmly against the top surface 48 of far wall 26. Spacer 102 also clamps the insulated end of cable 12 with cable-receiving recess 42 of near wall 24. A pair of latch arms 106 proximate each end of spacer 102 extend into a respective latching cavity 50 extending through latching flange 52 at each end of housing 20, and latch arms 106 are urged slightly together during placement of spacer 102 on housing 20, and their ends 108 have latching surfaces 110 which engage forward end surfaces 54 of the latching flange 52 when latch arms 106 resile after completing their passage through latching cavity 50. Spacer 102 has end sections 112 extending beyond latch arms 106 and over the top surfaces of flanges 52 of housing 20.
Cable 12 is then folded back over spacer 102 as seen in FIG. 3 until it is parallel to the termination plane and spaced a distance D equal to at least about two cable thicknesses between the centers of the cable portions. It is preferable not to bend the cable about a radius more sharply than the one described.
Retainer 114 is then secured to the assembly thus formed. A pair of latch posts 116 at each end of retainer 114 have latching surfaces 118 at ends thereof which extend past an end section 112 and latch over a respective latching flange 52 of housing 20, and retainer 114 engages against end sections 112 of spacer 102 and firmly secures cable 12 to the connector assembly 10 and provides cable strain relief.
A method of terminating conductors by laser welding is generally described in U.S. patent applications Ser. Nos. 769,552 filed Aug. 26, 1985 and 652,778 filed Sept. 19, 1984 and assigned to the assignee hereof. The present invention includes a method of laser welding for right-angle termination, where the conductor is disposed at right angles to the axis of the terminal. The laser welded joints are as strong as the wire, the electrical connection to the terminal is about as large as the wire diameter, and the connection will not deteriorate in vibration. The preparation of the cable end, the wiping of conductors into slots and the laser welding by precise computer control are easily incorporated into an automated cable harness assembly. The resistance of the welded wires at their terminations is smaller and more uniform than that of slot terminated wires. The elimination of tine projections from the terminals, and the elimination of wire ends extending beyond the terminals, eliminates geometry which is known to act as antennae, and thus substantially lessens reflection and crosstalk.
The present invention also includes a unique ground bus suitable for the connector and method of the present invention, and also unique conductor-connecting terminal sections.
Housing 20 of the connector may easily be adapted to accommodate different diameters of conductor wires by simply varying the width of channels 44,46 of the central wall 28, grooves 98 of ground bus 94, and slots 90 of terminals 18.
The connector of the present invention may easily be adapted for use with individual transmission cables by providing suitable strain relief therefor and appropriate cable spacing.
Other variations may be made as required in the present invention such as latching means or the structure of the contact sections of the terminals within the spirit of the invention and the scope of the claims. | A double row connector terminates transmission cable, with selected terminals for grounding to provide programming. Signal conductors are terminated to terminals in a housing by being held in interference fit in longitudinal slots of respective terminals and laser welded thereto. Ground conductors are similarly held in grooves of a ground bus in the housing and are laser welded thereto. Selected signal conductors are also laser welded to the ground bus as well as respective terminals to convert the terminals to grounds. The conductors are disposed in a termination plane transverse to the connector requiring right angle termination to the terminals. The insulated cable is then doubled back over a dielectric spacer secured to the housing over the terminations, and a retainer is latched to the housing to clamp the cable and provide strain relief. Terminals and a ground bus are specially designed for the connector and the laser welding termination method. | 8 |
CROSS REFERENCE TO PRIORITY APPLICATIONS
This is a U.S. national stage of application No. PCT/EP2010/007254, filed on 30 Nov. 2010. Priority is claimed German Application No. 10 2010 013 853.3 filed 1 Apr. 2010, the content of which is/are incorporated here by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hydraulic solenoid control valve, in particular, a hydraulic 3/2-solenoid control valve embodied as a double-seated valve in a cartridge design.
2. Description of Related Art
From the state of the art, e.g. 3/2-solenoid control valves including a magnetic actuator are known. This type of hydraulic valves offers two different switching positions for three different connection lines. With the two different switching positions, e.g. a pressure line P is selectively connected to a pressure-less tank line T, or an operating line A is selectively connected to the tank line T.
SUMMARY OF THE INVENTION
It is an object of one embodiment of the invention to provide a hydraulic solenoid control valve that is very compact and operates free of leakage oil even under high pressures, while being manufactured at low costs.
A hydraulic solenoid control valve, in particular a hydraulic 3/2-solenoid control valve, comprises a valve housing, a solenoid and a valve spindle. A valve chamber is integrated into the housing. This valve chamber comprises a first valve seat bore as a connection to a first line, in particular a pressure line, a second valve seat bore as a connection to a second line, in particular an operating line, and a free aperture to a third line, in particular a tank line. The aperture is referred to as “free”, since it connects the valve chamber to the third line in any switching position of the valve. The valve spindle is at least partially arranged within the valve chamber and is linearly moved by the solenoid. Further, the valve spindle comprises, within the valve chamber, a first sealing surface facing the first valve seat bore and a second sealing surface facing the second valve seat bore, such that selectively the first valve seat bore or the second valve seat bore can be closed. In addition, the valve spindle protrudes from the valve chamber through the second valve seat bore and through the second line toward the solenoid. Due to the protrusion of the valve spindle from the valve chamber, the valve spindle can be connected to the solenoid or can be partially integrated into the solenoid. In case the second valve seat bore is closed, the valve spindle is pulled into the second valve seat bore by a differential-area-ratio through the pressure of the second line, in particular the operating line. This arrangement including a differential area ratio promotes a sealing of the second valve seat bore free of leakage oil.
This differential-area-ratio is in particular achieved in that a sealing diameter of the valve spindle outside the valve chamber is larger than a diameter of the second valve seat bore. The sealing diameter is defined at a seal between the valve spindle and the solenoid.
Preferably, the differential-area-ratio is obtained by configuring the diameter of the valve spindle outside the valve chamber to be larger than the bore diameter of the second valve seat bore. Therewith, the pressure of the second line in front of the valve chamber can support the force of the pressure spring, when the second valve seat bore is closed, and pull the second sealing surface into the second valve seat bore.
Preferably, the first sealing surface comprises a convex surface, in particular a ball. Further preferably, the second sealing surface comprises a cone surface, in particular a cone ring surface. By linearly displacing or moving the valve spindle, the first valve seat bore is closed by the convex surface or the second valve seat bore is closed by the cone surface, selectively. Therewith, selectively the first line, in particular a pressure line, is connected to the third line, in particular a tank line, or the second line, in particular an operating line, is connected to the third line. A seizure in the switching position under pressure is effectively prevented by the ball valve embodiment including the convex surface.
In a preferred embodiment, a pressure spring is arranged between the first valve seat bore and the valve spindle. In the variant including a ball, the inventive valve may therefore be referred to as a spring-loaded ball-cone-seat valve.
In a further preferred embodiment, it is provided that the second sealing surface, in particular the cone surface, seals the second valve seat bore in a de-energized state of the solenoid, and that the first sealing surface, in particular the convex surface, seals the first valve seat bore in an energized state of the solenoid. The preferably provided pressure spring serves to press the second sealing surface of the valve spindle into the second valve seat bore in a de-energized state.
In a further preferred embodiment, the valve spindle comprises at least two parts. For this purpose, the valve spindle comprises a first part and a second part, wherein the first part is guided to be linearly movable in the solenoid and the second part is screwed into the first part. Consequently, the second part is fixedly connected to the first part and is linearly movable together with the first part. In particular for providing the differential-area-ratio, this two-part form of the valve spindle is especially easy to assemble. Therewith, in particular the sealing diameter can be configured to be larger than the bore diameter of the second valve seat bore.
In addition, it is preferably provided that a seal, in particular a groove ring seal, is arranged between the valve spindle and an armature space of the solenoid. Said seal is disposed at the already discussed sealing diameter between the valve spindle and the solenoid. Particularly preferred, the armature space is always freely connected to the third line, in particular the tank line, via a connection channel extending through the valve spindle. Therewith, a pressure generation in the armature space upon a possible leakage of the groove ring seal is prevented. The connection channel within the valve spindle extends from the armature space through the valve spindle into the valve chamber. As already described, the valve chamber is always freely connected to the third line, in particular the tank line.
Further, the invention preferably comprises a filter, in particular in the first line. Particularly preferred, the filter is arranged outside the valve chamber directly in front of the inlet into the first valve seat bore. The filter prevents pollution of the oil and in particular a pollution of the two valve seats.
In a further preferred embodiment, the first valve seat bore is disposed directly opposite to the second valve set bore.
In a preferred embodiment, the solenoid comprises a coil, an armature, a pole core as well as a gap between the pole core and the armature. The pole core comprises a borehole along the longitudinal axis of the valve spindle and provides an accommodation and a linear guidance for the valve spindle. Further preferably, the inventive solenoid valves comprise a control unit for the solenoid. By said control unit, the solenoid can be switched between energized and de-energized.
Further, the invention comprises a hydraulic cartridge solenoid control valve, in particular a hydraulic cartridge 3/2-solenoid control valve, comprising an afore-described hydraulic solenoid valve, wherein the housing is configured to be at least partially inserted into a valve adapter. Said valve adapter is located in a component which integrally accommodates the cartridge 3/2-solenoid control valve. Particularly preferred, the first line, in particular the pressure line, and the second line, in particular the operating line, are directed radially or vertically outwardly with respect to the longitudinal axis of the valve spindle. In addition, O-ring seals are preferably arranged laterally of the outwardly directed first and second lines on the surface of the valve housing, such that these lines can be connected pressure-tight by inserting the cartridge housing. Particularly preferred, the valve housing comprises circumferentially extending ring channels for this purpose. Starting at these ring channels, a plurality of radially directed channels for the first line and/or a plurality of radially directed channels for the second line may preferably lead to the valve chamber.
Further, it is preferred that the hydraulic cartridge solenoid control valve comprises a volume compensation unit including a tank compartment. This volume compensation unit including a tank compartment is integrated into the valve housing or connected to the valve housing by a flange. The tank compartment is preferably connected to the third line. The valve is preferably structured along the longitudinal axis of the valve spindle as follows: The valve chamber including the valve spindle is arranged in the center of the chamber. On one side of the chamber, the volume compensation unit including the tank compartment is integrated or connected by a flange. On the other side of the valve chamber, the solenoid is mounted. Therewith, the hydraulic cartridge solenoid control valve can be inserted into a component with the volume compensation unit to the fore. The solenoid and in particular a plug at the solenoid preferably protrude from the component. In a preferred embodiment, the tank compartment of the volume compensation unit is slightly pressure-loaded by a volume compensation piston and a compensation spring/pressure spring.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail based on the accompanying drawing, in which:
FIG. 1 is a schematic switching symbol for the inventive hydraulic 3/2-solenoid control valve according to one embodiment in a de-energized position;
FIG. 2 is the schematic switching symbol for the inventive hydraulic 3/2-solenoid control valve in an energized state,
FIG. 3 is the inventive hydraulic 3/2-solenoid control valve in a de-energized position,
FIG. 4 is the inventive hydraulic 3/2-solenoid control valve in an energized position, and
FIG. 5 is a detail of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, an embodiment of the invention is described in more detail with reference to FIGS. 1 to 5 .
FIG. 1 shows switching symbol for a hydraulic 3/2-solenoid control valve 1 in a de-energized position. The pressure line P is connected to the tank line T. The operating line A is blocked. FIG. 2 shows the switching symbol of the hydraulic 3/2-solenoid control valve 1 in an energized state. The pressure line P is blocked. The operating line A is connected to the tank line T.
In the following, the switching position of FIG. 1 is shown with reference to FIG. 3 . FIGS. 4 and 5 show the switching position of FIG. 2 .
FIG. 3 shows a sectional view of the hydraulic 3/2-solenoid control valve in a de-energized state. The hydraulic 3/2-solenoid control valve 1 comprises a housing 2 , a valve chamber 3 integrated into the housing 2 , a solenoid 4 and a valve spindle 5 . The valve spindle 5 moves in a longitudinal direction along a valve axis 38 .
The valve chamber 3 comprises a first valve seat bore 6 as a connection from the pressure line P to the valve chamber 3 and a second valve seat bore 7 as a connection from the operating line A to the valve chamber 3 . Further, a free aperture 8 to the tank line T is formed at the valve chamber 3 . The first valve seat bore 6 is located directly opposite the second valve seat bore 7 in a longitudinal direction. The free aperture 8 is also formed as a borehole, wherein the borehole of the free aperture 8 is arranged vertically (perpendicularly) with respect to the first valve seat bore 6 and the second valve seat bore 7 . In addition, a diameter of the first valve seat bore 6 is considerably smaller than a diameter of the second valve seat bore 7 .
The valve spindle 5 has a split structure that comprises a first part 12 and a second part 13 being screwed into the first part 12 and thus fixedly connected to the first part 12 . The second part 13 extends from the interior of the valve chamber 3 through the second valve seat bore 7 toward the solenoid 4 . The first part 12 is disposed completely outside the valve chamber 3 .
The second part 13 of the valve spindle 5 comprises a first sealing surface, embodied as a convex surface 9 (see in particular FIG. 5 ) on a side thereof facing the valve seat bore 6 . Said convex surface 9 is formed by a ball 10 . The ball 10 is embedded into a face side recess of the valve spindle 5 , in particular of the second part 13 . In addition, a shoulder is formed at the valve spindle 5 , in particular at the second part 13 . A valve pressure spring 14 is supported on said shoulder. The convex surface 9 is arranged within said valve pressure spring 14 . The valve pressure spring 14 is further supported at the front face of the first valve seat bore 6 . Said front face can also be referred to as sealing surface or lateral surface of the first valve seat bore 6 . Due to this arrangement of the valve pressure spring 14 , the valve spindle 5 is loaded toward the solenoid 4 . In a de-energized state, this results in an opening of the first valve seat bore 6 .
At the second valve seat bore 7 , the valve spindle 5 , in particular the second part 13 , comprises a second sealing surface, embodied as a cone ring surface 11 , within the valve chamber 3 . Said cone ring surface 11 is formed about the complete circumference of the valve spindle 5 . In a de-energized state of the solenoid 4 , said cone ring surface 11 is pushed onto the second valve seat bore 7 and therewith seals the operating line A with respect to the valve chamber 3 .
The solenoid 4 comprises a coil 16 , an armature 17 , and a pole core 18 . The coil 16 is wound about the armature 17 and the pole core 18 . The armature 17 and the pole core 18 are arranged in series along the longitudinal valve axis 38 . In the pole core 18 , a borehole is formed along the longitudinal valve axis 38 . Said borehole forms a linear guide 19 for at least a portion of the valve spindle 5 , in particular a portion of the first part 12 of the valve spindle 5 . In an energized state, a gap 20 being as small as possible exists between the pole core 18 and the armature 17 . In the de-energized state, said gap 20 is larger. The solenoid 4 further comprises a connecting line or voltage supply 21 for connecting a control unit to the hydraulic 3/2-solenoid valve 1 . The armature 17 and the pole core 18 are embedded into a sleeve 23 . Further, an insulation 24 exists between the sleeve 23 and the coil 16 .
The pole core 18 and the armature 17 are arranged in a so-called armature space 22 . Said armature space 22 is located within the sleeve 23 . The operating line A is sealed with respect to said armature space 22 by a specific seal, in particular a groove ring seal 25 . Said groove ring seal 25 is arranged between the valve spindle 5 , in particular the first part 12 , and the pole core 18 . A connection channel 15 is extending within the valve spindle 5 . Said connection channel 15 connects the armature space 22 to the valve chamber 3 . Since the valve chamber 3 is always freely connected to the tank line T, also the armature space 22 is always pressureless. The connection channel 15 is formed by a longitudinal borehole along the longitudinal valve axis 38 in the valve spindle 5 as well as by boreholes being vertical with respect to the longitudinal valve axis 38 from the surface of the valve spindle 5 to the longitudinally extending borehole. Due to the split structure of the valve spindle 5 , in particular, the longitudinal borehole can be formed along the longitudinal valve axis 38 inside the valve spindle 5 .
The housing 2 comprises a base housing component 26 , a first valve chamber insert 27 and a second valve chamber insert 28 . The first valve chamber insert 27 and the second valve chamber insert 28 together form the valve chamber 3 . The hydraulic 3/2-solenoid control valve 1 is structured and assembled as follows: An annular extension 29 is disposed at the solenoid 4 . A part of the second valve chamber insert 28 is embedded into said extension 29 . The second valve chamber insert 28 in turn accommodates the first valve chamber insert 27 . The sleeve 23 of the solenoid 4 extends to the second valve chamber insert 28 and is connected thereto. The complete unit comprises solenoid 4 , second valve chamber insert 28 and first valve chamber insert 27 is screwed into the base housing component 26 . For this purpose, an internal thread is formed at the base housing component 26 , and a corresponding external thread is formed at the extension 29 of the solenoid 4 . The individual housing components are sealed against each other.
In addition, the housing 2 comprises a cap 30 . The cap 30 encases the solenoid 4 and sits on the base housing component 26 .
A drilled insert 35 is formed inside the first valve chamber insert 27 . The first valve seat bore 6 is formed in said drilled insert 35 . In addition, a filter 36 is arranged in the first valve chamber insert 27 . Said filter 36 is disposed outside the valve chamber 3 and in the pressure line P.
In addition, a volume compensation unit 37 including the tank compartment 31 is integrated inside the base housing component 26 . Said volume compensation unit 37 including the tank compartment 31 comprises a volume compensation piston 32 , a compensation spring/length compensation spring 33 and a bearing 34 for the compensation spring 33 . The tank compartment 31 is connected to the tank line T. The volume compensation piston 32 defines a wall of the tank compartment 31 . The piston 32 is slightly spring-loaded by the compensation spring 33 . The compensation spring 33 is supported against the volume compensation piston 32 on one side thereof and against the spring bearing 34 on the other side thereof. The front face of the spring bearing 34 is screwed into the base housing component 26 .
The hydraulic 3/2-solenoid control valve 1 is constructed substantially rotation-symmetrically with respect to the longitudinal valve axis 38 . The pressure lines P, the operating lines A and the tank lines T deviate from said symmetry. The pressure line P and the operating line A end at respectively at least one position on the circumferential surface of the base housing component 26 . At this position, ring channels 39 are formed. Said ring channels 39 are sealed with O-ring seals 40 , when the 3/2-solenoid control valve 1 , embodied as a cartridge valve, is inserted into a corresponding receptacle.
FIG. 4 shows the hydraulic 3/2-solenoid control valve 1 according to the embodiment in the energized state. Herein, it is clearly visible that the valve spindle 5 was moved to the left compared to the illustration of FIG. 3 . Consequently, the operating line A is directly connected to the valve chamber 3 and thus with the tank line T and the tank compartment 31 via the second valve seat bore 7 . The pressure line P is blocked by the seating of the ball 10 in the first valve seat bore 6 and is therefore not connected to the valve chamber 3 .
FIG. 5 shows a detail of FIG. 4 . Based on this illustration, particularly the differential-area-ratio can be explained. It shall be noted that said differential-area-ratio is used upon a closed second valve seat bore 7 and thus in the de-energized valve position shown in FIGS. 1 and 3 . As shown in FIG. 5 , the valve spindle 5 comprises a sealing diameter D 1 at the groove ring seal 25 . The second valve seat bore 7 has an inner diameter D 2 . In a region between the groove ring seal 25 and the second valve seat bore 7 , the valve spindle 5 has a smallest diameter D 3 . When the second valve seat bore 7 is closed, the pressure in the operating line A acts on the following surfaces of the valve spindle 5 : The first surface is calculated by (D 2 2 /4*π)−(D 3 2 /4*π). The second surface is calculated by (D 1 2 /4*π)−(D 3 2 /4*π). Due to the fact that the first surface is smaller than the second surface, the operating pressure acts to the right in the shown illustration, when the second valve seat bore 7 is closed. Therewith, the valve pressure spring 14 is supported and the cone surface 11 is pulled into the second valve seat bore 7 .
Based on the shown embodiment, it was explained how a hydraulic 3/2-solenoid control valve 1 , in particular with a cartridge design, can be formed for an operation free of leakage oil. In the de-energized switching position, shown in FIG. 3 , the side of the valve spindle 5 formed as the cone surface 11 is pushed into the second valve seat bore 7 of the operating line by the pressure spring 14 and therewith blocks the connection of said line with respect to the tank in an oil-tight manner. On the magnet side, the valve spindle 5 is radially formed with a groove ring seal 25 with respect to the armature space 22 . The sealing diameter D 1 of the valve spindle 5 toward the armature space 22 is larger than the second valve seat bore 7 . Therewith, there results a defined area ratio between the cone seat and the sealing diameter D 1 of the armature space 22 . If the operating line A is pressurized, a differential force is generated through the area ratio between the operating line and the sealed armature space 22 , which force pulls the valve spindle 5 toward the solenoid 4 and acts in addition to the elastic force against the second valve seat bore 7 . The sealing effect increases with increasing pressure in the operating line A. The solenoid 4 is preferably configured such that a switching against the elastic force plus differential force is prevented. In this position, the pressure line P and the tank line T are connected to each other.
In the energized switching position according to FIG. 4 , the operating line A is pressureless, wherein the valve spindle 5 seals, with its ball 10 , the pressure line P in an oil-tight manner against the elastic force. A consumer connected through the pressure line P, can now be effectively sealed until the rated operating pressure is reached. Said operating pressure is dependent on the magnetic force. In this switching position, the operating line A is connected to the tank line T without pressure. Therewith, no pressure or only a small dynamic pressure can build up in the operating line A.
The embodiments of the proposed 3/2-solenoid control valve are applicable according to embodiments of the invention also for other valve designs, independent from the cartridge design and independent of the number of lines and/or switching positions. In particular a combination of ball seat and cone seat in a valve, in particular on a valve spindle, and/or the differential-area-ratio are applicable for other valves according to the invention.
Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | A solenoid distribution valve has a housing, a valve chamber integrated in the housing and a first valve seat bore for connection to a first line, a second valve seat bore as a connection to a second line and a clear opening to a third line, an electromagnet, and a valve lifter that can be moved by the electromagnet. A valve lifter within the valve chamber includes a first sealing surface facing the first valve seat bore and a second sealing surface facing the second valve seat bore that are optionally closable. The valve lifter extends out of the valve chamber through the second valve seat bore to the electromagnet. When the second valve seat bore is closed, the valve lifter is drawn, via a differential pressure ratio, by the pressure in the second line, into the second valve seat bore. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of prior U.S. application for patent Ser. No. 08/027,406 filed Mar. 8, 1993, now U.S. Pat. No. 5,371,454.
TECHNICAL FIELD
This invention relates to battery chargers, and in particular, to a system for charging and maintaining charge in an infrequently used battery.
BACKGROUND OF THE INVENTION
Batteries in seasonal vehicles such as boats, farm equipment, RVs, in some military equipment, antique cars, and other vehicles used infrequently or only seasonally tend to lose their charge, requiring recharging at various use intervals. Conventional fast battery chargers are large and cumbersome, use a substantial amount of electricity, and charge at a faster rate than the battery can accept. When being charged with a conventional fast charger, the voltage and amperage of the battery will typically rise at a faster rate than the battery potential. Thus, when the voltage and amperage reach a level indicating that the battery is fully charged, the battery charger will be disconnected or turned off. The battery will then begin to equalize the voltage, amperage and potential, with the voltage and amperage levels dropping and the potential increasing until equalization is reached. Because of the variation in the voltage, amperage, and potential levels at the time full charge is indicated, the battery will actually be charged to only about 80% of its capacity following equalization. Thus, the prior art fast chargers cannot charge a battery to 100% of its capacity.
Batteries repeatedly charged in this fashion reduces the capacity of the battery such that the battery will begin to lose the ability to accept a full 100% charge of the original capacity. Additionally, the use of a fast battery charger often causes rapid expansion of the battery fluid and the generation of gases, thus requiring the removal of the battery caps while charging the battery. Failure to remove the caps may result in explosion of the caps causing damage or total destruction of the battery. Thus, marine, recreational vehicle, and other infrequently used batteries are protected under substantially shorter warranty periods, often less than one-half the length of the warranty periods for regularly used batteries, such as car batteries.
Trickle chargers, another conventional type battery charger, are slow battery chargers, charging the battery with only one-to-three amps of charge at a time. A slow charge will bring the battery to full charge and alleviates having to remove the battery caps while charging. However, if left on the battery for an extended length of time after the battery has obtained full charge, the trickle charger will damage the battery and may destroy it completely.
Due to the slow rate at which the trickle charger charges the battery, the charger must be connected to the battery a substantial period of time prior to the use of the boat or vehicle, prohibiting spontaneous use thereof.
In one attempt to overcome the foregoing problems, fast and slow battery chargers were designed to include built in features for automatic turn off of the charger once the voltage of the battery indicated a full charge. In such chargers, once the voltage drops to a predetermined level, the charger is automatically turned back on to again recharge the battery until the voltage reaches the full charge level. Although the battery is automatically recharged, this cycling process reduces the life of the battery. Depending upon the cycling range of the particular charger, the user may decide to use the vehicle at a point where the voltage of the battery has dropped to a level where the charger is about to begin recharging the battery.
Many fishing boats have a driving battery and two 12-volt batteries connected as a 24-volt power source for operation of a trolling motor. Thus, three chargers were required for charging each of the three batteries simultaneously.
SUMMARY OF THE INVENTION
The passive battery charger of the present invention overcomes the foregoing and other problems associated with prior art battery chargers by utilizing a continuous slow charge process, along with the capability of charging multiple batteries at the same time. A first embodiment battery charger includes at least two 12-volt transformers each connected in a circuit to at least one positive and one negative battery cable or terminal, with a light bulb connected in the circuit to regulate the amperage of the charging current flowing from the transformer to the battery. The light bulb further visually indicates the status of the charge on the battery in that the brightness of the light is inversely proportional to the battery charge. The circuit is further configured to prevent sparks when the charger is hooked up to the battery in reverse position or when the cables accidentally come into contact with one another. When the cables are connected in reverse position to the battery, the light bulb in the circuit is brightly illuminated. On the other hand, the bulb is dimly illuminated when the cables are properly connected to the battery.
The flow of current in the circuit from the transformer is reduced as the resistance of the battery increases with the increased charge. As the battery reaches a full charge, the resistance of the battery is balanced with a maximum output of the transformer. The light bulb in the circuit line regulates the amperage of current flowing from the transformer to the battery as it is charged. The light bulb further allows for the back down of current produced by the transformer as a result of the increased resistance from the battery during charging. Thus, the charger may remain continuously connected to the battery without reducing the life of the battery through cycling or overcharging, and without damage to the transformer. Due to the low amperage charging process, the battery charger uses very little electricity, resulting in very low operational costs.
In fishing boats wherein the trolling motor is powered by two 12-volt batteries connected in series to provide 24-volts, the battery charger of the present invention allows each 12-volt battery in the 12/24-volt configuration to be charged at the same time without removing the series connection between the two batteries. By providing at least two transformers, there is capacity for charging the driving battery for the boat at the same time as the trolling batteries. One transformer is connected through a split circuit to two sets of battery cables. The set of cables is connected to the driving battery with the second set of cables connected to one of the 12-volt trolling batteries. The remaining 12-volt trolling battery is connected to the cables from the second transformer. Thus, the circuits for charging the series connected batteries are isolated from one another to allow charging operations without requiring removal of the series connection.
In the event a battery must be charged in a relatively short period of time, in a second embodiment of the invention, a manual switch is connected to bypass the light bulb in the circuit, thereby allowing the flow of higher voltage and amperage to the battery for a fast charge. An indicator light is connected to the switch to indicate a fast charge condition. When the switch is in the off position, the passive slow charge condition resumes to maintain charge. Thus, in addition to the low operational costs and the continuous low amperage multiple battery charging capabilities, the charger may be converted to a fast charge device for charging of the battery in a few hours.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following Detailed Description taken in conjunction with the accompanying Drawings in which:
FIG. 1 is an electrical schematic of a battery charger incorporating a first embodiment passive battery charger of the present invention;
FIG. 2 is a drawing showing an obtuse view of the housing, and cables of the battery charger of FIG. 1;
FIG. 3 is a drawing similar to FIG. 2 with the top half of the housing removed to show the interior of the battery charger of FIG. 1;
FIG. 4 is a side view of the battery charger of FIG. 3;
FIG. 5 is a drawing of the circuit board showing the wiring connections for the battery charger of FIG. 1;
FIG. 6 is a rear view of the housing of FIG. 1;
FIG. 7 is a top view of a boat, illustrating the positioning of and the charging of the trolling motor and driving motor batteries;
FIG. 8 is an obtuse view of a mounting bracket for mounting the battery charger to a receiving surface;
FIG. 9 is a schematic circuit diagram for a battery charger incorporating a second embodiment of the present invention;
FIG. 10 is an obtuse view of the housing of the battery charger of FIG. 9;
FIG. 11 is a view similar to FIG. 10 with the top of the housing removed to show the interior of the battery charger of FIG. 9: and
FIG. 12 is a side view of the battery charger of FIG. 11.
DETAILED DESCRIPTION
Referring now to the Drawings and more particularly to FIG. 1 thereof, there is shown a schematic diagram of the electrical circuit of a battery charger 10 incorporating a first embodiment passive battery charger of the present invention for charging 12-volt, acid or jell, regular or deep, cycle batteries. As illustrated in FIG. 1, the battery charger 10 is equipped with a conventional AC plug 12 insertable into a 120-volt AC receptacle and having opposite prongs 14 and 16 and a ground prong 18. The opposite AC prongs 14 and 16 are connected to the opposite ends of the primary coil 20 of a first transformer 22, and to the opposite ends of the primary coil 24 of a second transformer 26. The first transformer 22 is preferably a conventional 12-volt/3 amp transformer. The top of the secondary coil 28 of first transformer 22 is connected through line 30 to the anode of rectifier diode 32, the cathode of which is connected to a battery cable 34, in turn selectively connected at its distal end to the positive post of a 12-volt battery 36. The negative post of battery 36 is selectively connected through a battery cable 38 to the anode of rectifier diode 40, the cathode of which is connected to a one and one-half amp light bulb 42, which functions as a current limiter in the circuit 44. Although in the preferred embodiment of the invention the current in the circuit is limited by the one and one-half amp light bulb, other conventional current limiters may be used in place thereof. To complete the circuit, light bulb 42 is connected through line 46 to the bottom of secondary coil 28.
When charging a second battery 48, the current from transformer 22 is split between the first circuit 44 and a second circuit 50. The top side of the secondary coil 28 is connected through line 30 to the anode of diode 52, the cathode end of which being selectively connected to the positive post of the battery 48 through a battery cable 54. The negative post of the battery 48 is selectively connected through a battery cable 56 to the anode of a diode 58, the cathode end of which is connected to a second one and one-half amp light bulb 60, functioning as a current limiter for the second circuit 50. To complete the circuit 50, the light bulb 60 is connected to the bottom of the secondary coil 28 of first transformer 22 through lines 62 and 46.
As further illustrated in FIG. 1, the second transformer 26 is a conventional 12-volt/1.5 amp transformer, having a primary coil 24 and a secondary coil 64. The top of secondary coil 64 is connected through line 66 to the anode of a diode 68, with the cathode end selectively connected through battery cable 70 to the positive post of a third 12-volt battery 72, which may be a single battery or may be tied in series to battery 48 as illustrated by dotted line 49 to provide a 24-volt battery. The negative post of the battery 72 is selectively connected through battery cable 74 to the anode of a diode 76, the cathode end of which is connected to a third one and one-half amp light bulb 78, thereby limiting the current flowing through the circuit 80 to the battery 72 to a maximum of one and one-half amps. To complete the circuit 80, the light bulb 78 is connected through line 82 to the bottom of the secondary coil 64 of the transformer 26. When charging a single battery or three separate batteries, any one or combination of the circuits 44, 50, or 80 may be used.
Referring now to FIGS. 2, 3, and 4, the transformers 22 and 26 along with the components of circuits 44, 50 and 80 are mounted within a housing 90, having a first half 92 and second half 94. The first half 92 defines a top 96, a first side 98, and a second side 100. The second half forms a bottom 102, a third side 104, and a fourth side 106. In the first and second sides 98 and 100, respectively, are vents 108 to allow air circulation through the battery charger 10. In the third side 104 are windows 110 for observing the illumination of the light bulbs 42, 60, and 78. The first half 92 of the housing is attached to the second half 94 of the housing using conventional fasteners 112.
Referring now to FIGS. 2, 3, and 6, battery cables 70 and 74 from circuit 80 and battery cables 54 and 56 from circuit 50 exit the housing 90 through opening 120 in the fourth side 106 of the housing 90. Battery cables 70 and 74 are paired with battery cables 54 and 56 to facilitate connection of the two pairs of cables to a pair of 12-volt batteries cross-connected for generation of 24-volts. Battery cables 34 and 38 from circuit 44 pass through opening 122 in the fourth side 106 of the housing 90. The cord 124 for the conventional AC plug 12 exits the housing 90 through an opening 126 in the fourth side 106 of the housing 90.
Referring now to FIGS. 3 and 4, the light bulbs 42, 60, and 78, are mounted in a circuit board 130 extending parallel to the third side 104 of the housing 90. The base 132 of each of the bulbs 42, 60 and 78, is secured in the circuit board 130 with a rubber grommet 134. Each of the windows 110 in the third side 104 of the housing 90 has a rubber grommet 136 positioned therein for contacting the lamp 138 of each of the bulbs 42, 60, and 78.
As illustrated in FIG. 5, in addition to supporting the base 132 of each of the light bulbs 42, 60, and 78, the circuit board 130 provides the surface through which the connections 140 between the diodes 32, 40, 52, 58, 68, and 76 and the battery cables 34, 38, 54, 56, 70, and 74, respectively, and the connections 142 between the diodes 32, 52, and 68 and the lines 30 and 66 from the transformers 22 and 26.
When charging a battery using the charger 10 of the present invention, the current limiting light bulb 42 in each circuit 44, for example, limits the current delivered to the battery 36 to a maximum of 1.5 amps, that being the maximum amps the bulb 42 is capable of pulling. As the charge on the battery 36 increases, the voltage and amperage delivered by the transformer 22 are repelled by the increasing charge on the battery 36, thereby reducing the amps of the current passing through the bulb 42. Thus, as the charge on the battery 36 approaches 100% and the amps flowing through the bulb decrease, the illumination of the bulb 42 dims, thereby providing a visual indication at all times of the charge on the battery.
The light bulb 42 prevents damage to the battery 36 or transformer 22 by limiting the current flow to 1.5 amps in the event of a reversed polarity attachment of the cables 34 and 38 to the battery 36, in which case the bulb 42 is brightly illuminated. Similarly, the light bulb in each of the circuits 44 and 50 limits the current through each circuit, such that a short in any one of the circuits or the connection of a dead battery to any one of the circuits will not interfere with the current flowing through the remaining circuit. The configuration of the circuits 44, 50, and 80 further prevents sparking when connecting the cables 34 and 38, 54 and 56, and 70 and 74 to the batteries 36, 48, and 72, respectively.
In the event batteries 48 and 72 are connected in series as shown at 49 for generation of 24-volts, the isolation of circuits 50 and 80 from one another allows batteries 48 and 72 to be charged simultaneously without removing the series connection 49. Pairing of the cables 54 and 56 of circuit 50 and the cables 70 and 74 of the circuit 80 as they exit the housing 90 facilitates proper connection to the paired batteries 48 and 72. The passing of cables 34 and 38 through a separate opening in the housing 90 reduces the possibility of connecting both sets of cables receiving power from a single transformer 22 to the paired batteries 48 and 72, thereby facilitating the isolation of the circuits charging the paired batteries 48 and 72. By splitting circuits 50 and 44 from a single transformer 22, the passive charger 10 is kept small and relatively light weight.
Referring now to FIG. 7, there is shown a top view of a fishing boat 150. Most fishing boats 150 are equipped with two 12-volt batteries 152 and 154, to provide the power through a line 156 for driving a trolling motor 158, as well as a 12-volt battery 160 for providing the power for starting the gas engine 162 of the boat 150. The batteries 152, 154, and 160 are typically positioned as illustrated in FIG. 7, although any number of configurations may exist due to the design of the particular boat 150. Battery cables 34 and 38 of the battery charger 10 are connected to the driving battery 160. Cables 70 and 74 are connected to either trolling battery 154, or 152 and cables 54 and 56 connected to the remaining trolling battery. There is also a series connection 49 between batteries 152 and 154. For convenience, the passive battery charger 10 may be permanently mounted in the boat 150 using two of the mounting brackets 164 as shown in FIG. 8, and remain continuously connected to batteries 152, 154, and 160, at all times. A flange 163 of each bracket 164 is inserted into the lower vent slot 230 of sides 218 and 220 of the housing 90 and is attached to the receiving surface of the boat 150 with conventional fasteners by placing the fasteners through an opening 166 in each bracket 164.
Referring now to FIG. 9, there is shown a battery charger 170 incorporating a second embodiment of the passive battery charger of the present invention. As illustrated in FIG. 9, the battery charger 170 is equipped with a conventional AC plug 172 insertable into a 120-volt AC receptacle, with opposite prongs 174 and 176 and a ground prong 178. The opposite AC prongs 174 and 176 are connected to the opposite ends of the primary coil 180 of a transformer 182, having a secondary coil 184. The top of the secondary coil 184 is connected through line 186 to the anode of a rectifier diode 188, the cathode of which is selectively connected through a battery cable 190 to the positive post of a 12-volt battery 192. The negative post of the battery 192 is selectively connected through a battery cable 194 to the anode of a diode 196, the cathode end of which is connected to a 1.5 amp light bulb 198, functioning as a current limiter for the circuit 200. The passive battery charger 170 operates in the same way as previously described with respect to the circuits 44, 50, or 80 of the first embodiment passive battery charger 10. The battery charger 170 is, however, capable of producing a fast charge through the use of a double pole, double throw, switch 202 which functions to bypass the current limiting bulb 198. When in the closed position, the switch 202 creates a loop in the circuit bypassing the bulb 198, and closes the circuit such that a small indicator light 204 connected between the switch and line 186 is illuminated to indicate that the battery charger 170 is operating in a fast charge condition. It is understood that although the switch 202 is shown connected to a single circuit 200 in the charger 170, the switch may be connected to multiple circuits, such as those of the first embodiment battery charger 10. Likewise, each of the circuits of the first embodiment battery charger 10 may be separately equipped with switches 202 such that any one or more of the driving motor battery or trolling motor battery may simultaneously receive a slow charge while the remaining battery or batteries receive a fast charge from a single charging unit 10.
Referring now to FIGS. 10, 11, and 12, the transformer 182 is mounted within a housing 210 having a first half 212 and a second half 214. The first half 212 forms a top 216, a first side 218, and a second side 220. The second half forms a bottom 222, a third side 224, and a fourth side 226. The first half 212 is connected to the second half 214 with conventional fasteners 228 along the first side 218 and second side 220. The first side 218 and second side 220 have vents 230 therein to allow circulation of air through the charger 170. A window 232 in the third side 224 allows the illumination of the bulb 198 to be observed there through. Mounted on the third side 224 of the housing 210 is a lever 234 for actuating the switch 202. Also mounted on the third side 224 of the housing 210 is the small indicator light 204 for indicating a fast charge condition when illuminated. The cord 236 of the conventional AC plug 172 exits the housing 210 through an opening 238 in the fourth side 226. A second opening 240 in the side 226 provides an exit for the battery cables 190 and 194 from the housing 210.
Referring now to FIGS. 11 and 12, the base 250 of the bulb 198 is mounted in a circuit board 252 and secured therein by a rubber grommet 254. The circuit board 252 extends parallel to the third side 224. A second grommet 256 is placed within the window 232 for contacting the lamp 258 of the bulb 198. | A battery charger for simultaneously slow charging and thereafter maintaining a charge in a plurality of plate-type batteries includes a first transformer connected through a circuit loop to a first battery wherein the circuit loop includes a rectifier, and a current limiter and visual indicator of the charge level of the battery. A second transformer is connected through another circuit loop to one battery and through a third circuit loop to a second battery. The circuit loop of the first transformer may be connected to a first battery with one of the circuit loops of the second transformer being connected to a second battery connected in series to the first battery thus allowing the two loops to remain isolated from each other and allow for charging of the series connected batteries without removal of the series connection. In a second embodiment of the invention, a switch is connected in the loop to bypass the current limiter to allow a fast charge condition. A small indicator light is connected to the switch to indicate a fast charge condition. Thus, the charger may be switched from a slow passive charge condition to a fast charge condition, and back to a slow charge condition. | 8 |
TECHNICAL FIELD
[0001] This description relates to increasing the mechanical or acoustic impedance of a headphone cushion to reduce the audibility of outside sounds without substantially increasing the axial stiffness of the cushion.
BACKGROUND
[0002] For background, reference is made to commonly owned U.S. Pat. Nos. 4,922,452 and 6,597,792, the entire contents of which are hereby incorporated by reference.
SUMMARY
[0003] In a first aspect, a headset including an earcup having a front opening adapted to be adjacent to the ear of the user, a baffle disposed within the earcup to define front and rear cavities, a cushion extending around the periphery of the front opening of the earcup and constructed and arranged to accommodate the ear of the user, the cushion having a first density, an inner radial portion, and an outer radial portion opposite the inner radial portion, a cushion cover substantially surrounding the cushion to form a headphone cushion assembly, and a high impedance component having a second density and being disposed proximate the outer radial portion to increase the transmission loss of the cushion along a radial direction.
[0004] In various embodiments, the headset can include a transducer inside the earcup. The second density can be substantially higher than the first density. In some embodiments the high impedance component is interposed between the outer radial portion of the cushion and the cushion cover. In others embodiments, the high impedance component is interposed between the inner radial portion of the cushion and the cushion cover. In some embodiments, the high impedance component is disposed adjacent the cushion cover. In some embodiments, the high impedance component includes a substantially rigid ring. In still further embodiments, the high impedance component includes a colloidal ring, such as, for example, a gel layer. In some embodiments, the high impedance component includes polyurethane foam. In some embodiments, the cushion cover includes a plurality of openings extending along the inner radial portion of the cushion to acoustically add the volume of the cushion to the volume of the earcup and enhance passive attenuation of the headset. In some embodiments, the cushion cover includes an acoustically transparent mesh along the inner radial portion of the cushion to acoustically add the volume of the cushion to the volume of the earcup and enhance passive attenuation of the headset. In some specific embodiments, the outer radial portion of the cushion has an average area density greater than about 0.03 g/cm 2 and the headphone cushion assembly has an axial stiffness per contact area less than about 8 gf/mm/cm 2 . In some embodiments, the headphone cushion assembly has an axial stiffness per contact area less than about 4 gf/mm/cm 2 .
[0005] The headphone cushion assembly may be a substantially toroidal shape, such as for example, circumaural or is supra-aural. In some embodiments, the headset further includes a microphone inside the earcup adjacent to a driver; and active noise reducing circuitry intercoupling the microphone and the driver constructed and arranged to provide active noise cancellation. In some embodiments, the inner radial portion of the cushion cover is constructed and arranged to furnish additional damping to help smooth an audio response at an ear of a user and control stability when the headset is not being worn on a head of the user. In some embodiments, the cushion cover includes a plurality of openings such that the volume of the cushion is acoustically added to the volume of the earcup. In some specific embodiments, the cushion adheres to the cushion cover with a peel strength greater than about 0.1 gf/mm, and in other embodiments, the foam adheres to the cushion cover with a peel strength greater than about 0.4 gf/mm. In some embodiments, the cushion includes open cell foam and has a bulk density between about 2 pcf and about 6 pcf, and can have an elastic modulus between about 1 kPa and about 10 kPa, or between about 2 kPa and about 5 kPa. In some embodiments, the high impedance component includes a silicone material.
[0006] In a second aspect, an apparatus for blocking sound includes an earcup having a front opening adapted to be adjacent the ear of a user; and a headphone cushion assembly extending around the periphery of the front opening of the earcup, the cushion assembly having an inner radial portion, and an outer radial portion opposite the inner radial portion and the ratio of radial stiffness to axial stiffness per contact area of the headphone cushion assembly is greater than about 10 cm 2 . In some embodiments, a stiffening component is attached to the outer radial portion of the headphone cushion assembly. In still other embodiments, a stiffening component is attached to the outer radial portion of the headphone cushion assembly. In various embodiments, the stiffening component includes a substantially rigid support ring and/or a gel layer. In some embodiments, the headphone cushion assembly may be a substantially toroidal shape.
[0007] In another aspect, a headphone cushion assembly includes a cushion comprising an open cell foam and adapted to be adjacent the ear of the user; an inner cushion cover substantially covering the inner portion of the cushion proximate the ear of the user; the inner cushion cover comprising a plurality of openings, and an outer cushion cover substantially covering the outer part of the cushion distal to the ear of the user, the outer cushion cover comprising a first layer having an average area density less than about 0.03 g/cm 2 and a second layer attached to the first layer, the second layer having an average area density greater than about 0.045 g/cm 2 .
DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagrammatic view of a headphone assembly on a head.
[0009] FIG. 2A is a perspective drawing of one embodiment of a headphone cushion including a stiffening component and FIG. 2B is plan view of one embodiment of a headphone cushion.
[0010] FIG. 3 is a sectional view of a headphone cushion including a stiffening ring.
[0011] FIG. 4 is a sectional view of a headphone cushion including a high density layer.
[0012] FIG. 5 is a drawing of an outer cover including a high density layer.
[0013] FIG. 6 is a sectional view of an earcup assembly.
[0014] FIG. 7 is a graph of sound attenuation through a headphone assembly including a stiffening ring as measured on a test fixture.
[0015] FIG. 8 is a graph of sound attenuation through a headphone assembly including a stiffening ring as measured on a head.
[0016] FIG. 9 is a graph of sound attenuation through a headphone assembly including a high density layer as measured on a test fixture.
[0017] FIG. 10 is a graph of sound attenuation through a headphone assembly including a high density layer as measured on a head.
[0018] FIG. 11 is a sectional view of a test method for measuring axial stiffness.
[0019] FIG. 12 is a sectional view of a test method for measuring radial stiffness.
[0020] FIG. 13 is a sectional view of a test method for measuring peel strength.
[0021] FIG. 14 is a sectional view of an earcup assembly including active noise reducing circuitry.
DETAILED DESCRIPTION
[0022] Referring to FIG. 1 , there is shown a diagrammatic view one embodiment of a headphone assembly 100 worn by a user on a human head 102 having ears 104 . The headphone assembly 100 includes suspension assembly 106 , transducer assembly 108 , stiffening component 110 , headphone cushion 112 , audio opening 114 , and cover 116 . Headphone assembly 100 is shown covering and substantially surrounding ears 104 and accordingly, is referred to as circumaural headphones. Alternatively, headphone assembly 100 may be an on-the-ear (supra-aural) set of headphones. Stiffening component 110 serves to increase the impedance of the outer cover of the cushion thus reducing the sound transmission through headphone assembly 110 , thereby improving the isolation from outside noise for the headphones listener. In some embodiments, the stiffening component does not appreciable change the axial stiffness of the cushion so as not to impact the comfort of the headphone assembly to the user. An earcup assembly is formed by the combination of transducer assembly 108 , headphone cushion 112 , and cover 116 . Optionally, stiffening component 110 may be included in the earcup assembly. The earcup assembly may have a substantially toroidal shape to fit over or on the ear 104 .
[0023] The stiffening component 110 may be shaped in the form of a support ring that encircles the headphone cushion 112 . Cover 116 may extend over the exterior portion of headphone cushion 112 . Cover 116 may extend over the interior portion of headphone cushion 112 . Interior cavity 118 is formed by transducer assembly 108 , headphone cushion 112 , and head 102 . Headphone cushion 112 may be constructed of open cell foam. If headphone cushion 112 is constructed of open cell foam, audio openings 114 allow the volume of the headphone cushion 112 to combine with interior volume 118 . This combined volume is useful for tuning the audio characteristics of headphone assembly 100 . Audio openings 114 are constructed and arranged to furnish additional damping to help smooth the audio response of headphone assembly 100 and control stability when headphone assembly 100 is not being worn. For a description of tuning using audio openings and combined volume, reference is made to U.S. Pat. Nos. 4,922,542 and 6,597,792.
[0024] The bulk density of foam is defined as the density of the foam in its expanded state. In some implementations, headphone cushion 112 may have a bulk density of about 2 to about 6 pounds-mass per cubic foot (pcf). In one implementation, the headphone cushion 112 includes a foam having a bulk density of about 5 pcf. In some implementations, the headphone cushion 112 includes a foam having an elastic modulus between 1 and 10 kiloPascals (kPa). In one implementation, the headphone cushion 112 includes a foam having an elastic modulus between about 2 and about 5 kPa. High stiffness foam is useful to reduce sound transmission through headphone cushion 112 . However, foam that is too stiff may reduce the comfort of the headphones.
[0025] Referring to FIGS. 2A and 2B , in one embodiment of a headphone cushion assembly 200 includes gasket 202 , inside cover 204 , outside cover 206 , stiffening ring 208 , and front surface 210 . The headphone cushion assembly for only one ear is depicted but it is understood by persons of ordinary skill in the art that headphone cushion assemblies for two ears are included in a set of headphones. Front surface 210 fits against the head of the listener while the headphone is in use. Gasket 202 fits between the headphone cushion assembly 200 and transducer assembly 108 to affect a seal at the interface. Inside cover 204 and outside cover 206 may be one continuous piece of material in some embodiments. Inside cover 204 and outside cover 206 may be made of plastic, leather, leatherette, or leather-like plastic (also known as pleather) material. In FIG. 2A , stiffening ring 208 is attached to the outside of outside cover 206 . Alternatively, stiffening ring 208 may be attached to the inside of outside cover 206 . Headphone cushion assembly 200 may have a substantially toroidal shape to fit over or on the shape of the human ear. In some embodiments, the headphone cushion assembly 200 further includes a plurality of openings 212 ( FIG. 2B ) disposed along the inside cover 204 to expose the underlying foam and thereby increase the effective volume of the earcup by the volume of the underlying foam. In these embodiments, passive attenuation is enhanced and additional damping is provided to help smooth the audio response and control stability of the feedback loop of the active noise reduction system, as more fully explained in commonly owned U.S. Pat. No. 6,597,792.
[0026] Referring to FIG. 3 , there is shown a section drawing of another embodiment of a headphone cushion assembly. In FIG. 3 , Headphone cushion assembly 300 includes opening 302 , gasket 304 , outside cover 306 , inside cover 308 , stiffening ring 310 , headphone cushion 312 , and front surface 314 . In this embodiment, stiffening ring 310 is attached to the inside of outside cover 306 .
[0027] The radial stiffness of headphone cushion assembly 300 is measured by compressing one side of headphone cushion assembly 300 in a direction along the radius of it's toroidal shape and measuring the force necessary to compress headphone cushion assembly 300 a known distance. Stiffness is calculated by dividing the force by the distance compressed. Likewise, the axial stiffness is calculated in a direction along the axis of the toroidal shape. The radial directions are perpendicular to the axial direction. To achieve high attenuation simultaneously with good comfort, the ratio of radial stiffness to axial stiffness per contact area should be greater than 10 cm 2 .
[0028] Referring to FIG. 4 , there is shown a section drawing of another embodiment of a headphone cushion assembly. To increase the mechanical impedance of the outer cushion cover, a high density layer 400 is attached to the inside of outside cover 306 . Outside cover 306 forms a first layer. High density layer 400 forms a second layer. In one embodiment, outside cover 306 has an average area density of less than 0.03 g/cm 2 and high density layer 400 has an average area density greater than 0.045 g/cm 2 . The high density layer may be a highly compliant, massive, and dissipative material. The high density layer may be silicone gel. The high density layer may optionally be applied to only the outside of outside cover 306 or to both the inside and outside of outside cover 306 .
[0029] Referring to FIG. 5 , there is shown a headphone cushion cover before it is spread around a headphone cushion. In this state, the headphone cushion cover is a flat piece of cloth or similar material shown as cover 500 . High density layer 400 is shown attached to cover 500 . The average area density is defined as the mass per unit area averaged over the area shown in FIG. 5 . For example, the average area density of cover 500 is the total mass of cover 500 divided by the area of cover 500 as shown in FIG. 5 . The average area density of high density layer 400 is the total mass of high density later 400 divided by the area of layer 400 as shown in FIG. 5 .
[0030] Referring to FIG. 6 , there is shown a section drawing of a headphone cushion assembly pressed between top plate 630 and bottom plate 640 . Bottom plate 640 is immovable as shown by hash marks 650 . Cover 600 covers cushion 670 . Outside portion 680 of cover 600 is outside of the headphone cushion assembly and extends from the contact point between cover 600 and top plate 630 to the contact point between cover 600 and bottom plate 640 . Inside portion 690 of cushion 600 is inside of the headphone cushion assembly and extends from the contact point between cover 600 and top plate 630 to the contact point between cover 600 and bottom plate 640 . Audio openings 660 are also shown in cover 600 .
[0031] In one embodiment, the headphone assembly has audio openings in the portion of the cover that extends over the interior surface of the headphone cushion. The audio openings function to acoustically add the volume of the headphone cushion 112 to the interior volume 118 which enhances passive attenuation. The audio openings are approximately 30% of the total surface area of the interior surface of the cover. The approximate volume of the interior cavity is 100 cc, the half-mass of the headphone assembly is 95 g, and the stiffness of the headphone cushion is 100 g-force/mm. The approximate volume of the open-cell foam in the headphone cushion is 40 cc, so the combined volume of the interior cavity and headphone cushion is 140 cc.
[0032] At frequencies above the resonance of the axial bouncing mode of the headphone, a second mode of radial, through-cushion transmission may exist—especially in low-impedance cushions with audio openings. Increased radial stiffness through the addition of a stiffening ring, or increased mass and damping through the application of a silicone gel can improve the cushion's attenuation of outside noise. Increased cushion cover stiffness, mass, and damping generally correlate with higher attenuation. The axial stiffness affects the comfort of the headphones. Low axial stiffness is desired to improve comfort. For a headphone cushion assembly without a stiffening ring, the axial stiffness is approximately 80 gf/mm. For the same headphone cushion with a stiffening ring, the axial stiffness is approximately 100 gf/mm. The stiffening ring increases the radial stiffness much more than the axial stiffness. This difference in stiffness creates headphones that have both excellent comfort and high attenuation of outside noise.
[0033] Referring to FIG. 7 , there is shown a graph of measured sound attenuation (in dB) vs frequency (in Hertz) through one embodiment of a headphone assembly while the headphone assembly is mounted on a test fixture. As opposed to the human head, the test fixture is flat so that it does not have leaks between the headphone cushion and the test fixture. Also, the fixture is rigid compared with the much more compliant surface (the skin) of a human test subject. The shapes of the curves in FIG. 7 depend on the physical dimensions and material properties of the headphone assembly under test. Curve 700 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, but no interior cover. Curve 702 shows the sound attenuation through a headphone assembly that has both an exterior cover and an interior cover over the headphone cushion. Curve 704 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, holes in the interior cover (or no interior cover), and a stiffening ring attached to the outside of the exterior cover. Curve 704 shows the benefit of high attenuation from the stiffening ring above approximately 500 Hz. The attenuation of the headphones with the stiffening ring and holes in the interior cover is approximately equal to the attenuation from the headphone assembly with both inside and outside covers. The advantage of using holes in the interior cover and the stiffening ring rather than interior and exterior covers is that the volume of the headphone cushion can be used to help tune the audio characteristics of the headphones. Since the volume encapsulated by the cushion may be utilized, the headphone assembly may be made smaller and still achieve performance similar to a larger set of headphones that has no holes in the interior cover.
[0034] Referring to FIG. 8 , there is shown a graph of measured sound attenuation (in dB) vs frequency (in Hertz) through one embodiment of a headphone assembly while the headphone assembly is mounted on human heads. The curves in FIG. 8 represent data averaged from many individual heads. The set of headphones does not perfectly fit on each head, so leaks occur between the set of headphones and the heads. The shapes of the curves in FIG. 8 depend on the physical dimensions of the heads, and the physical dimensions and material properties of the set of headphones under test. Curve 800 shows the sound attenuation through a set of headphones that has an exterior cover over the headphone cushion, but no interior cover. Curve 802 shows the sound attenuation through a set of headphones that has both an exterior cover and an interior cover over the headphone cushion. Curve 804 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, holes in the interior cover (or no interior cover), and a stiffening ring attached to the outside of the exterior cover. Curve 804 shows the benefit of high attenuation from the stiffening ring above approximately 500 Hz.
[0035] Referring to FIG. 9 , there is shown a graph of measured sound attenuation (in dB) vs frequency (in Hertz) through one embodiment of a headphone assembly while the headphone assembly is mounted on a test fixture. The shapes of the curves in FIG. 9 depend on the physical dimensions and material properties of the headphone assembly under test. Curve 900 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, but no interior cover. Curve 902 shows the sound attenuation through a headphone assembly that has both an exterior cover and an interior cover over the headphone cushion. Curve 904 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, holes in the interior cover (or no interior cover), and a high density layer attached to the inside of the exterior cover. Curve 904 shows the benefit of high attenuation from the high density layer above approximately 500 Hz. The attenuation of the headphones with the high density layer and holes in the interior cover is approximately equal to the attenuation from the headphone assembly with both inside and outside covers.
[0036] Referring to FIG. 10 , there is shown a graph of measured sound attenuation (in dB) vs frequency (in Hertz) through one embodiment of a headphone assembly while the headphone assembly is mounted on human heads. The curves in FIG. 10 represent data averaged from many individual heads. The shapes of the curves in FIG. 10 depend on the physical dimensions of the heads, and the physical dimensions and material properties of the set of headphones under test. Curve 1000 shows the sound attenuation through a set of headphones that has an exterior cover over the headphone cushion, but no interior cover. Curve 1002 shows the sound attenuation through a set of headphones that has both an exterior cover and an interior cover over the headphone cushion. Curve 1004 shows the sound attenuation through a headphone assembly that has an exterior cover over the headphone cushion, holes in the interior cover (or no interior cover), and a high density layer attached to the inside of the exterior cover. Curve 1004 shows the benefit of high attenuation from the high density layer above approximately 500 Hz.
[0037] Referring to FIG. 11 , there is shown a sectional view of a test method for axial stiffness. Force 1100 is applied to moveable plate 1110 which pushes on top plate 1120 . Bottom plate 1130 is held immovable as shown by hash marks 1140 . Headphone cushion assembly 1180 includes cushion 1150 , cover 1160 , and attachment plate 1170 . Headphone cushion assembly 1180 is pressed between top plate 1120 and bottom plate 1130 during the axial stiffness test. Distance 1195 is the distance between top plate 1120 and bottom plate 1130 . Audio openings 1190 are also shown in cover 1160 . The steps of the axial stiffness test procedure are as follows. Determine the nominal clamp force of a headset (adjusted for medium size) as the force applied by the ear cushions to parallel plates with outer surfaces spaced 138 mm apart. Place headphone cushion assembly 1180 between top plate 1120 and bottom plate 1130 . Apply a series of known forces 1100 to top plate 1120 in the direction perpendicular to top plate 1120 . The range of forces 1100 should include the nominal clamp force of the corresponding headset. Record the resulting distances 1195 and forces 1100 . Calculate the axial stiffness of the headphone cushion assembly as the slope of the forces 1100 as a function of distances 1195 in gf/mm at the nominal clamp force of the corresponding headset. Determine the contact area of the headphone cushion assembly as the total area of cover 1160 which is in contact with bottom plate 1130 when the nominal clamp force of the corresponding headset is applied as force 1100 . Calculate the axial stiffness per contact area as the axial stiffness divided by the contact area of the cushion in gf/mm/cm 2 . Forces 1100 should be applied at less than or equal to 100 gf/min. Alternatively, forces 1100 may be applied rapidly if two minutes settling time is allowed before measurement of the forces 1100 and distances 1195 .
[0038] Referring to FIG. 12 , there is shown a sectional view of a test method for radial stiffness. Top plate 1220 and bottom plate 1230 are held immovable as shown by hash marks 1240 . Headphone cushion assembly 1280 includes cushion 1250 , cover 1260 , and attachment plate 1270 . Top plate 1220 and bottom plate 1230 have adhesive surfaces to hold headphone cushion assembly 1280 in place between top plate 1220 and bottom plate 1230 . Distance 1295 is the distance between top plate 1220 and bottom plate 1230 . Indenter 1297 pushes on the headphone cushion assembly in a radial direction. Indenter 1297 is a rigid cylinder with a diameter of 3 mm. Resultant force 1200 pushes back on indenter 1297 . Audio openings 1290 are also shown in cover 1260 . Before the radial test procedure is performed, distance 1295 must be determined. Using the test setup in FIG. 11 , set force 1100 to 150 gf and measure resultant distance 1195 . Set distance 1295 in FIG. 12 equal to resultant distance 1195 from the test setup in FIG. 11 with force 1100 equal to 150 gf. The steps of the radial stiffness test procedure are as follows. Clamp headphone cushion assembly 1280 between top plate 1220 and bottom plate 1230 . Position the axis of indenter 1297 in the central plane of cushion 1250 , and along a direction perpendicular to the curvature of the cover 1260 's outer surface when viewed along a direction perpendicular to plates 1220 and 1230 . Push indenter 1297 3.8 mm (from the position of initial contact) into headphone cushion assembly 1280 . After 2 minutes settling time, record the resultant force 1200 on indenter 1297 . Calculate the radial stiffness of the headphone cushion assembly as the resultant force 1200 divided by the 3.8 mm indenting distance in gf/mm.
[0039] Referring to FIG. 13 , there is shown a sectional view of a test method for peel strength. Force 1300 is applied to pull up cover sample 1310 from foam sample 1320 . Foam sample 1320 is mounted to plate 1330 which is held immovable as shown by hash marks 1340 . Cover sample 1310 is a rectangular piece of outer cover material from the headphone cushion assembly with a width greater than 100 mm and a length greater than 150 mm. Foam sample 1320 is a rectangular piece of foam from the headphone cushion assembly which has a width and length larger than cover sample 1310 . Cover sample 1310 is placed over foam sample 1320 such that the inner surface of cover 1310 contacts foam sample 1320 . 10 kPa of force is then applied evenly to cover sample 1310 on foam sample 1320 for 2 minutes to allow cover sample 1310 to adhere to foam sample 1320 . The steps of the peel strength test procedure are as follows. Using a load cell with a resolution of at least 0.01 N to measure force 1300 , peel cover sample 1310 from foam sample 1320 at a rate of 60 mm/min in the direction perpendicular to foam sample 1320 . According to one test protocol, cover sample 1310 can be peeled so that the angle between cover sample 1310 and foam sample 1320 remains within 10° of perpendicular. Record average force 1300 as the average force measured over a peel distance of 100 mm. The peel direction should be perpendicular to the direction of gravity. Calculate the peel strength as average force 1300 divided by the width of the cover sample 1310 in gf/mm.
[0040] Referring to FIG. 14 , there is shown a sectional view of an earcup assembly with noise reducing circuitry. Reference is made to U.S. Pat. No. 6,597,792, the entire contents of which are hereby incorporated by reference. Driver 1400 is seated in earcup 1410 with driver plate 1420 extending rearward from a lip 1430 of earcup 1410 to a ridge 1440 with microphone 1450 closely adjacent to driver 1400 and covered by a wire mesh resistive cover 1460 . Cushion 1470 covers the front opening of earcup 1410 and includes foam 1480 .
[0041] Other implementations are also within the scope of the following claims. | A headset including an earcup having a front opening adapted to be adjacent to the ear of the user, a baffle disposed within the earcup to define front and rear cavities, a cushion extending around the periphery of the front opening of the earcup and constructed and arranged to accommodate the ear of the user, the cushion having a first density, an inner radial portion, and an outer radial portion opposite the inner radial portion, a cushion cover substantially surrounding the cushion to form a headphone cushion assembly, and a high impedance component having a second density and located near the outer radial portion to increase the transmission loss of the cushion along a radial direction. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a thermostatic expansion valve for a refrigeration or heat-pump circuit as per the preamble of claim 1 .
[0002] In transcritical refrigeration or heat-pump circuits, the high-pressure side dissipation of heat takes place usually above the critical pressure of the refrigerant which is used. On account of the resulting temperature gradient in the gas cooler, the pressure at the gas cooler outlet is a degree of freedom in the circuit process. Specifically in circuit processes which use CO 2 as refrigerant, it is highly important to adjust the high pressure into an optimum-efficiency range as a function of the ambient or gas-cooler-outlet temperature. In CO 2 air conditioning systems, usually only fixed throttles or externally-controlled expansion elements are used in the regulation of the refrigerant circuit. The former do not permit any adaptation of the high pressure to the process boundary conditions during operation. Externally-controlled expansion elements must for this purpose be regulated by electronic control elements whose responsiveness is insufficient in particular for automotive applications. Accordingly, said externally-controlled expansion elements cannot offer a sufficient level of operating reliability. Further disadvantages result from a high susceptibility to failure and high development and purchase costs.
[0003] DE 102 49 950 B4 discloses an expansion valve for high-pressure refrigeration systems having a valve seat and a valve element which interacts with the valve seat, and a spring device which acts on the valve element, and an adjusting device for the spring arrangement, with the spring arrangement having at least one first spring and one second spring which act on the valve element. The first spring defines a working range and the second spring has a spring force which can be varied by the adjusting device.
[0004] U.S. Pat. No. 6,012,300 discloses an expansion valve which has a chamber in which refrigerant is enclosed. The chamber is delimited by a diaphragm which acts indirectly on a valve element. The diaphragm is however also exposed to the high-pressure-side refrigerant. In particular, the active faces which are acted on by the refrigerant which is enclosed in the chamber and the further active faces which are acted on by the high-pressure-side refrigerant which passes from the gas cooler are identical. With the described expansion valve, no safeguard against high pressure above a maximum permissible value (for example 120 bar) is possible. In addition, a reliable start-up behaviour is not possible at inlet temperatures at the expansion valve above the critical temperature of the refrigerant. An operationally reliable application therefore cannot be realized with said expansion valve.
[0005] DE 10 2005 034 709.6 discloses a thermal expansion valve which has a first and a second active face which are coupled in terms of movement to a valve element. The first active face is part of an expandable separating device which comprises a chamber with a control charge in the thermal head. The temperature of the high-pressure-side refrigerant can be sensed in this way. By means of said expandable separating device of the thermal head, the temperature-dependent pressure of the control charge in the chamber is transmitted to a temperature-independent spring element which is connected to the second active face which is also subjected to the high pressure. By means of said embodiment, it is intended to obtain a high-pressure limiting function in the supercritical regulating range.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the invention to further develop an expansion valve which can adjust the high pressure of a refrigeration or heat-pump circuit which can be operated transcritically and also subcritically within an optimum range and can autonomously prevent an exceedance of a maximum permissible value.
[0007] Said object is achieved by means of an expansion valve as per the features of claim 1 . By using a thermally controllable actuating element whose actuating movement is coupled in terms of movement to a first active face of a first actuating element only when a temperature-dependent actuating movement of the second, that is to say of the thermally controllable actuating element acts counter to the actuating movement of the first active face of the first actuating element, it is made possible to provide a pressure limiting function or a safety function for preventing excessively high operating pressures, which requires no external activation.
[0008] Here, a temperature threshold value of the thermally activatable actuating element for an actuating movement is selected which corresponds to a temperature value of the MOT of the control charge. The temperature threshold value is the temperature at which the thermally controllable actuating element generates an actuating or stroke movement. The working characteristic curve of the thermally controlled actuating element has the same gradient as the working characteristic curves of the control charge in the superheated vapour state, but in the opposite direction. The safety function is obtained in this way. In addition, an absolute pressure limitation, that is to say the realization of the MOP function (maximum operation pressure), is permitted at all temperature levels. While the first actuating element is acted on with pressure by a high-pressure-side refrigerant passing from the inner heat exchanger and absorbs the temperature of said refrigerant, the working behaviour of the thermally activatable actuating element is independent of the refrigerant pressure.
[0009] According to a further advantageous embodiment of the invention, it is provided that a detachable mechanical coupling is provided between the first actuating element and the thermally activatable actuating element, and the thermally activatable actuating element engages on a first active face of the first actuating element or on a valve element which is connected to the first actuating element. Said mechanical coupling, which occurs above a predetermined temperature value, makes it possible, in normal operation at a conventional temperature threshold range, for the first actuating element to work independently of the thermally activatable actuating element, and the first control element is coupled in terms of movement to the valve element only when a further temperature rise takes place which demands the use of the safety function.
[0010] The control charge of the first control element is preferably provided in a chamber which is embodied in the manner of a diaphragm or bellows and absorbs the temperature of the high-pressure-side refrigerant. The active face of the first actuating element is acted on by the temperature-dependent pressure of the control charge in the chamber of the actuating element and also by the high pressure. The resulting pressure difference generates an adjusting force which sets the valve element in motion and, as a function of the throttle properties of the associated valve seat, opens a certain flow cross section.
[0011] It is preferably also possible for an additional, in particular preloaded spring element to be provided which intensifies the action counter to the high pressure. This has the result that an opening movement of the valve element takes place when the temperature-independent excess force, which is generated at the active face by the high pressure of the refrigerant system, is sufficient to overcome the preload of the in particular preloaded spring element and the force action of the chamber, as a result of which a passage between the valve seat and the valve element is opened or the cross section of the passage opening is enlarged.
[0012] The control charge of the chamber of the first actuating element preferably has a charge density which lies below its critical density. It is preferably additionally provided that a substance mixture is selected for the control charge which has a critical temperature which lies above the critical temperature of the refrigerant to be regulated. In this way, the control charge has, in most temperature threshold ranges, a two-phase state with a high vapour proportion. Only when the energy absorbed by the control charge is sufficient to completely evaporate the liquid phase, which is present as a function of the prevailing filling density, does the control charge pass into the superheated vapour state. Under said circumstances, in the event of a further temperature rise, a control pressure is generated with only a smaller gradient than in the previous, two-phase state of the control charge, which gradient is not equal to zero. The temperature value above which said physical effect occurs is referred to as MOT (maximum operating temperature). The associated pressure value for the control charge is referred to as MOP (maximum operation pressure). It is additionally preferably provided that the temperature-independent force of the thermally activatable actuating element corresponds to the increase of the control charge of the first actuating element in the superheated state. In the event of a further temperature rise in the superheated vapour state, the pressure rises with only a considerably smaller gradient than in the previous, two-phase state. On account of the adaptation of the thermally activatable actuating element to said gradient, the safety function is realized in that the thermally activatable and high-pressure-independent actuating element acts in the opposite direction with the same gradient, so that a maximum operating pressure can be set which, in a desired manner, corresponds to a horizontal pressure profile at a MOP level.
[0013] Said temperature value or temperature threshold value is preferably determined by the structural design of the thermally activatable actuating element. According to a first advantageous embodiment of a thermally activatable actuating element, it is provided that bimetal elements, in particular bimetal plates, which are stacked one on top of the other are provided. Said bimetal plates are for example arranged in the shape of a bellows. Said bimetal elements perform an actuating movement only above a certain temperature, as a function of their pre-setting.
[0014] A second alternative embodiment for the design of a thermally activatable actuating element provides that a diaphragm, a bellows or a spring element, in particular a spiral spring or a spring bellows, is produced from a shape-memory alloy. A temperature-dependent activation can in turn be made possible in this way.
[0015] A further alternative embodiment of the actuating element is provided by a filled, bellows-like spring element which is preferably filled with a medium which exists in the liquid state of aggregation above its vaporization pressure or below its saturation temperature.
[0016] Suitable charge media are for example oil or generally hydrocarbons with a high boiling point. Said temperature displacement transducer elements are preferably hermetically sealingly joined diaphragm, corrugated-tube, bellows elements or else cylinder-piston units which exert high actuating forces by means of thermal expansion of their liquid filling. Said elements can be designed such that their stroke-temperature characteristic curve begins only above a certain temperature.
[0017] It is preferably provided that the thermally activatable actuating elements have a pressure-independent device in order to preload them. It is made possible in this way for the temperature value at which the thermal safety function of the valve comes into action to be adjustable. A device of said type is preferably externally adjustable. An electronic or motor-driven activation can alternatively also be provided.
[0018] It is additionally preferably provided that the chamber of the first actuating element, in particular an inner contour of the chamber, is guided by a sleeve or webs. This makes it possible for deformations as a result of the action of the control charge to be prevented.
[0019] In a rest position of the valve element of the thermostatic expansion valve, it is preferably provided that a minimum passage opening is opened. This means that, when the temperature- and pressure-dependent excess force on the underside of the thermally activatable actuating element is not sufficient to overcome the preload of the latter, only an expediently predefined throttle cross section is opened, and the thermostatic expansion valve functions as a fixed throttle, as a result of which the high pressure in the circuit itself is set.
[0020] The scope of the present invention therefore encompasses a transcritical or subcritical refrigeration or heat-pump circuit with an inner heat exchanger which makes possible a thermostatic expansion valve with an autonomously settable overflow function or safety function without for example an additional relocation of lines at the evaporation inlet. At the same time, the thermostatic regulating capability of the COP-optimum high pressure can be maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention and further advantageous embodiments and refinements thereof are described and explained in more detail below on the basis of the examples illustrated in the drawings. The features which can be gathered from the description and from the drawings can be applied according to the invention individually or together in any desired combination. In the drawings:
[0022] FIG. 1 is a schematic illustration of a refrigerant circuit,
[0023] FIG. 2 shows a state diagram for explaining the function of a refrigerant circuit having the thermostatic expansion valve as specified in the introduction,
[0024] FIG. 3 shows a first embodiment of a thermostatic expansion valve,
[0025] FIGS. 4 a,b are a schematic illustration of a control charge characteristic curve and the action of the thermally activatable actuating element on the valve opening characteristic curve,
[0026] FIG. 5 shows a state diagram of valve stroke characteristic curves at different operating pressures,
[0027] FIG. 6 shows a second embodiment of a thermostatic expansion valve and
[0028] FIG. 7 shows a third embodiment of a thermostatic expansion valve.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 1 shows a refrigerant and/or heat-pump circuit 11 of an air-conditioning system. In a refrigerant compressor 12 , a gaseous refrigerant, in particular CO 2 , is compressed. The compressed refrigerant is supplied to a gas cooler 13 where a heat exchange takes place between the compressed refrigerant and the environment in order to cool the refrigerant. The refrigerant which leaves the gas cooler 13 passes to an inner heat exchanger 14 which is connected to an expansion valve 15 . The expansion valve 15 has the effect firstly of limiting the pressure of the refrigerant and secondly of regulating the pressure of the refrigerant at the outlet of the inner heat exchanger 14 . From the expansion valve 15 , the refrigerant passes to an evaporator 16 . In the evaporator 16 , the refrigerant absorbs heat from the environment. Arranged downstream of the evaporator 16 is an accumulator 17 in order to separate refrigerant of the gaseous phase and of the liquid phase and at the same time to collect liquid CO 2 . The accumulator 17 is in turn connected to the inner heat exchanger 14 .
[0030] The mode of operation of the air-conditioning system is now to be explained on the basis of the state diagram of FIG. 2 in which the pressure p is plotted against the specific enthalpy H. A refrigerant, for example CO 2 , in the gaseous phase is compressed in the refrigerant compressor 12 (A-B). The hot, highly-pressurized, transcritical refrigerant is then cooled in the gas cooler 13 and in the inner heat exchanger 14 (B-C and C-D). The pressure is reduced in the expansion valve 15 (D-E) in order to evaporate the now two-phase (gaseous and liquid phase) refrigerant in the evaporator 16 (E-F), and to thereby extract heat from the environment. The COP is determined by means of the ratio of the enthalpy change Δi in the step E-F and the enthalpy change ΔL in the step A-B, that is to say COP=Δi/ΔL.
[0031] The critical temperature of CO 2 lies at approximately 31° C., which is lower than the critical temperature (often >100° C.) of fluorohydrocarbons which have hitherto been used in air-conditioning systems. This has the result that the temperature of CO 2 at the outlet of the inner heat exchanger 14 can be higher than the critical temperature of CO 2 . In said state, the CO 2 itself does not condense at the outlet of the inner heat exchanger 14 . The pressure at the outlet of the inner heat exchanger 14 must therefore be regulated. If, therefore, the external temperature is high, for example in summer, it is necessary to set a high pressure at the outlet of the inner heat exchanger 14 in order to obtain a sufficient cooling power. The outlet temperature at the inner heat exchanger 14 is dependent inter alia on the refrigerant-side temperature at the gas cooler outlet, which is in turn dependent on the ambient temperature. This means that the temperature of the CO 2 at the outlet of the inner heat exchanger 14 can also be used for the regulation of the COP-optimized high pressure, which is otherwise dependent on the refrigerant-side gas cooler outlet temperature.
[0032] In the diagram as per FIG. 2 , the characteristic curves 21 ′ and 21 ″ illustrate the COP-optimized regulating region. The double arrow in between denotes a valve stroke range of 0 to approximately 75% of the valve stroke. Illustrated between the characteristic curve 21 ″ and the characteristic curve 21 ′″ is the overpressure regulating region. By means of a further opening of the valve stroke beyond approximately 75%, an excess pressure can be dissipated. The characteristic curve 21 ″″ represents a settable high-pressure limit for the refrigerant circuit 11 which is to be regulated. Said high-pressure limit can be designed to be variable.
[0033] FIG. 3 illustrates a first embodiment according to the invention of a thermostatic expansion valve 15 which permits operation of a refrigerant system as per a state diagram in FIG. 2 . The expansion valve 15 comprises a valve housing 26 which has a high-pressure side supply opening 27 which leads into a high-pressure space 28 . The high-pressure space 28 is connected by means of a passage opening 29 to a low-pressure side discharge opening 31 . The passage opening 29 has a valve seat 32 in which a valve element 33 is provided in a closed position and separates the supply opening 27 with respect to the discharge opening 31 .
[0034] Provided in the high-pressure space 28 is a first actuating element 36 which comprises a first active face 37 on which the valve element 33 is provided. A chamber 38 engages on said first active face 37 in the closing direction of the valve element 33 , which chamber 38 is embodied in the manner of a diaphragm or bellows.
[0035] Additionally provided is a spring element 39 which for example surrounds the chamber 38 and preferably engages on the active face 37 in a preloaded manner and in the same force direction as the chamber 38 . In coordination with the size of the valve element 33 or the length of its shank or a stop element which is provided in the high-pressure space 28 , a preload of the spring element 39 and/or of the chamber 38 is made possible.
[0036] The chamber 38 is preferably formed from a highly thermally conductive material. Provided in the chamber 38 is a control charge 41 whose pressure in the chamber 38 is temperature-dependent. When a high pressure acts on the high-pressure side, said high pressure acts against the active face 37 and opens the passage opening 29 if the acting high pressure has an excess force with respect to the preloaded spring element 39 and the pressure of the control charge 41 in the chamber 38 . The opening and closing movement is, in the COP-optimized regulating range, independent of a thermally activatable actuating element 46 which is likewise provided in the high-pressure space 28 .
[0037] In the exemplary embodiment as per FIG. 3 , the thermally activatable actuating element 46 engages on the first active face 37 opposite the chamber 38 and the spring element 39 , if provided. Alternatively, the actuating element 46 can also engage on the valve element 33 or additionally on the valve element 33 . The thermally activatable actuating element 46 is formed from bimetal plates which are stacked one on top of the other in the shape of a bellows. The bimetal plates can be preloaded by means of a pressure-independent device (not illustrated in any more detail), so that said bimetal places perform an actuating movement or a stroke movement only once the safety function is required. This is the case if the temperature of the refrigerant rises above the MOT. Accordingly, the preload of the bimetal plates or their material configuration is adapted to a temperature threshold value of said type.
[0038] In the event of a sufficient excess force of the high pressure with respect to the pressure force of the chamber 38 and of the spring element 39 , if provided, by means of a predefined stroke characteristic curve, the optimum cross section is opened and therefore the optimum high pressure (COP-optimized range) is set as a function of the high-pressure-side outlet temperature of the refrigerant at the inner heat exchanger.
[0039] The expansion valve 15 according to the invention makes possible an autonomously settable overpressure and safety function, so that the refrigerant circuit can operate with COP-optimized high pressure. FIG. 4 a is a schematic illustration of a characteristic curve 19 of a control charge in a chamber 38 of the first actuating element 36 , in which the pressure is plotted against the temperature up to the critical point. Since the control charge, which is present in two-phase form up to said point, passes into the single-phase, superheated gaseous state above the MOT value 20 for the circuit 11 , the pressure of the control charge continues to rise with only a considerably shallower gradient. The safety function can however only be obtained by means of a horizontal pressure profile from the MOT value 20 . Said further disadvantageous rise is compensated in one expedient embodiment of the present invention by means of the use of the thermally activatable actuating element 46 , whose characteristic curve is illustrated with 46 ′ in FIG. 4 a . In this way, a valve opening characteristic curve 22 is obtained which is illustrated in FIG. 4 b . Said valve opening characteristic curve 22 with the horizontal pressure profile at the MOP level leads to a maximum mass flow generation when the high pressure of the circuit 11 is situated thereabove, so as to result in a self-inhibiting generation of high pressure, because the temperature-induced pressure force of the chamber 38 , which acts in the closing direction of the valve element 33 , is compensated. The thermally activatable actuating element 46 can also act early on the opening cross section of the passage opening 29 , so that a rise of the high pressure above the MOP value is prevented.
[0040] It is additionally to be mentioned that, although the refrigerant-side gas cooler outlet temperature is the preferred regulating temperature in the circuit with regard to COP optimization, the high-pressure-side outlet temperature at the inner heat exchanger 14 can likewise be used for the purpose of regulating the high pressure in a COP-optimum range. For this purpose, the outlet states at the inner heat exchanger 14 which correspond to each COP-optimum gas cooler outlet state are determined either by means of simulation or testing for the circuit in which the thermostatic expansion valve 15 described by this invention is used. A COP-optimized pressure profile therefore results by means of the high-pressure-side outlet temperature at the inner heat exchanger 14 , and said COP-optimized pressure profile is the aim of the optimum valve stroke characteristic curve 22 as per the state diagram in FIG. 5 , in which the mass flow rate is plotted against the temperature. Said COP-optimum valve stroke characteristic curve 22 is restricted to one part, which is to be defined within the context of the application, of the entire valve stroke range, for example between 0 and 75%. This is illustrated in FIG. 2 by the characteristic curves 21 ′ and 21 ″. The double arrow 22 shows the COP-optimized regulating range. Beyond the upper limit of the latter, the overflow function comes into action. If a mass flow rate characteristic curve 23 of the throttle point is designed, above said upper limit, that is to say until 100% of the total valve stroke range is reached, so as to be sufficiently steep that such a mass flow rate can flow out from the high-pressure into the low-pressure side, and therefore a further rise in the high pressure of the system can be prevented, one obtains the safety function, as claimed by the present invention, for preventing excessively high system pressures.
[0041] By means of the arrangement of a thermostatic expansion valve 15 of said type at the evaporator inlet, one avoids complex line set relocation, as is necessary for example in the use of a thermostatic expansion valve as per the patent U.S. Pat. No. 6,012,300, since the valve described therein must absorb the refrigerant-side outlet temperature at the gas cooler—either by means of a local arrangement at the gas cooler outlet or by means of the relocation of a capillary line between the valve and gas cooler outlet.
[0042] FIG. 6 illustrates an alternative embodiment to FIG. 3 . In contrast to the latter, the thermally activatable actuating element 46 is produced as a spring element from a shape-memory alloy. Said actuating element 46 can be set in such a way that the stroke movement takes place only above a predetermined temperature threshold value. Here, the acting force can additionally also be determined by means of the cross section of the spring element. In addition, an electric activation of said thermally activatable actuating element 46 composed of the shape-memory alloy could also be possible. The further functions and variants described with regard to FIG. 3 likewise apply to this embodiment.
[0043] FIG. 7 illustrates a further alternative embodiment of a thermally activatable actuating element 46 to FIG. 3 . In said embodiment, a hydraulically filled, bellows-like spring element is provided which permits the overflow function or safety function. The charges of the thermally activatable actuating element 36 comprise for example different oils and hydrocarbons.
[0044] All of said features are in each case essential to the invention and can be combined with one another in any desired manner. | The invention relates to a thermostatic expansion valve having a valve element ( 33 ) which, for the throughflow of the refrigerant, closes and moves in the opening direction a valve seat ( 32 ) of a passage opening ( 29 ) arranged between the supply opening ( 27 ) and the discharge opening ( 31 ), and which is assigned to a first actuating element ( 36 ), the first actuating element ( 36 ) comprising a chamber ( 38 ) which is delimited with a first active face ( 37 ) and which contains a control charge ( 41 ), wherein an actuating element ( 46 ) is provided, which is thermally activated independently of the high pressure, the actuating movement of which actuating element ( 46 ) is coupled in terms of movement to the first active face ( 37 ) of the first actuating element ( 36 ) when a temperature-dependent actuating movement of the thermally activatable actuating element ( 46 ) acts counter to the actuating movement of the first active face ( 37 ) of the first actuating element ( 36 ), with a temperature threshold value of the thermally activatable actuating element ( 46 ) for an actuating movement being set to an identical value as the MOT (maximum operation temperature) of the control charge ( 41 ) of the first actuating element ( 36 ), which control charge ( 41 ) has a fluid density which lies below its critical density. | 5 |
BACKGROUND OF THE INVENTION
1. Field of The Invention
The apparatus of the present invention relates to excavating buckets. More particularly the present invention relates to a detachable finishing blade which can be easily positioned on different size excavation buckets and allow for the finishing of broad areas excavated, and allow movement of a greater capacity of material into the bucket.
2. General Background
In excavation of land utilizing a backhoe or the like apparatus, the backhoe is equipped with an excavation bucket, which in general comprises a bucket-shaped scoop mounted at the end of the arm of the backhoe, the bucket having a plurality of excavating teeth protruding from its bottom wall, so that it can excavate the land area, or the like, and move fill into the bucket for disposal, etc. Excavating buckets are also utilized to help complete an excavation project, following the filling of a ditch or pit, by smoothing out the dirt, packing it in, or scraping off the excess fill to flatten the area.
One of the shortcomings of the state of the art excavation bucket is the inability of the bucket to be easily utilized on the finishing work following excavation. Usually, the bucket, or the teeth on the front of the bucket have to be replaced by a blade so that the blade can be utilized to form a smooth finished surface as the blade is moved along the ground in the finishing method.
However, in the art, there is no system of excavation buckets which allows the easy adaptation of a typical excavation bucket by the attachment of a blade onto the front of the bucket, so that the bucket can be used to finish excavation and yet allow materials to continue to be loaded into the bucket following adaptation of the blade unit.
The prior art which was found as a result of a patentability search is being submitted herewith as part of the Art Statement and is incorporated herein by reference thereto.
Other objects of the invention will be obvious t those skilled in the art from the following description of the invention.
SUMMARY OF THE PRESENT INVENTION
The apparatus of the present invention solves the problems in the art in a simple and straight forward manner. What is provided is an improved excavating bucket, having a pair of sidewalls, a rear wall, a floor portion and an open front portion for receiving material thereinto; plurality of teeth members secured to the floor portion for digging into the material to be excavated; a finishing blade movably mounted to the bucket, the blade extending across a width greater than the width of the bucket opening, and having a forward edge for scraping; a raised channel formed on the upper face of the blade for engaging a plurality of the teeth members;
sidewall members extending from the outer edges of the blade for engaging the wall of the bucket, for defining an uninterrupted travelling space for material into the bucket; and adjustable support sleeves positioned between the blade and the bucket sidewalls to stabilize the blade on the bucket.
Therefore, it is a principal object of the present invention to provide an excavation bucket adapted with a finishing blade so that the bucket can be easily used to finish a job, and continue to function as an excavation bucket;
It is a further object of the present invention to provide a finishing blade for an excavation bucket which can be secured to the teeth of the bucket, and held in place by adjustable sleeves to allow the bucket to function as a finishing tool;
It is a further object of the present invention to provide a finishing blade system attachable to a standard excavation bucket, so that the blade can be removed easily, yet while in place held secure to undertake finishing jobs, and adjust to various size buckets; and
It is a further object of the present invention to provide a system for mounting a finishing blade on an excavation bucket which provides for a swivel mounting feature so that the blade can be mounted on different size buckets.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 illustrates an overall view of the preferred embodiment of the present invention;
FIG. 2 illustrates an overall top view of the preferred embodiment of the present invention;
FIG. 3 illustrates an overall view of the preferred embodiment of the present invention during a finishing procedure;
FIG. 4 illustrates an overall cutaway view of the mounting sleeve utilized in the preferred embodiment of the present invention;
FIG. 5 illustrates an overall view of the mounting sleeve utilized in the preferred embodiment of the present invention;
FIGS. 6A and 6B illustrate partial views of the mounting sleeves utilized in the preferred embodiment of the present invention;
FIG. 7 illustrates a partial side view of the blade mounted onto an excavation bucket tooth member in the preferred embodiment of the present invention;
FIG. 8 illustrates a partial view of the mounting rod showing further the swiveling of the rod mounted in place;
FIG. 9 illustrates a partial view of the plate utilized for engaging the tooth members in the mounting of the blade; and
FIG. 10 is a top view of the blade to be utilized in the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 through 10 illustrated the preferred embodiment of the present invention by the numeral 10. As illustrated in overall view in FIG. 1, apparatus 10 comprises an excavating bucket 12, of the type having a pair of upright side walls, 14, 16, a curved base portion 18, which extends from a rear upright portion 20, to the floor 22 of the bucket. There is further provided an upper portion 24, for connectedly engaging the bucket 12 to the arms 26 of a backhoe (not illustrated) or the like implement to excavate earth or the like material. Further, the excavating bucket 12 includes a plurality of excavating teeth members 30, along the front edge 32 of the floor 22, with each of the teeth members extending therefrom, and spaced apart to form the plurality of digging means. Each tooth includes a body portion 34 secured through welding or the like to the front edge 32 of floor 22, and terminate in a beveled edge 36 to form a point 38 that excavates the earth. The bucket as illustrated in FIG. 1 also defines a space 40, formed by the floor portion, and side walls, wherein materials excavated are moved into for clearing out the area.
As further illustrated in FIG. 1 in overall view is the means for transforming the excavating bucket 12 to a finishing implement, of the type to spread the upper level of dirt into a smooth layer, and to finish the edges of the area. This means includes a blade 42, extending from a distance greater across than the width of the bucket 12 itself, for defining a finishing blade there across. Further blade 42 includes a beveled front edge 44 to form the means to finish the surface very smoothly. Blade 42 would also include an under surface 46, which would be flat, and would allow for the packing of the smooth, finished area.
The blade 42 is mounted to the excavation bucket 12 through a unique mounting system 50 which allows for the secure mounting so the blade can be secure when in use, and provides for easy mounting and removal from the bucket 12. Further the manner in which the blade is mounted allows full access to the space 40 within the bucket 12 so that materials may still be moved into space 40 even with blade 42 mounted onto the bucket 12.
The mounting system 50 would further comprise an upper mounting plate 52, secured to upper surface 43 of blade 42, comprising a pair of end mounting members 54, welded or the like along the blade 42, and providing that plate 52 is raised from the upper surface 43 of plate 42, for defining a receiving space 56 therein. Preferably, as seen in FIG. 9, the end of plate 52 would have a lip 5 received into an opening 53 in mounting members 54, to hold it securely in place. Receiving space 56 would receive the beveled edge 36 of a plurality of the teeth 30 from bucket 12, so that the blade, when secured as seen in the figures, is centrally positioned along the front of bucket 12. Preferably, as seen in FIG. 1, the central most teeth 30 would be secured within the space 56, with the outer most teeth set free. There would be further provided additional front support gussets 55 spaced apart along the top of plate 52, and extending forward of plate 52 welded to the upper surface 43 of plate 42, so that the materials moving over plate 52 slide along the upper surface 57 of the members 55, and do not contact plate 52.
The mounting system would further comprise a pair of side walls 60 extending between the upper surface 43 of plate 42 and the front edges 17 of each side wall 14, 16 of bucket 12, so as to define a means to assure that the materials scraped by plate 42 during the operation, are channeled from the surface of the plate inwardly to the reduced opening in the space 40 of bucket 12. As illustrated in the figures, it is preferable that the position of side walls 60 be slightly tilted to the rear, so that the materials do not encounter a upright plate barrier, but are eased into the bucket space 40 by the rear-tilted side walls 60. In addition, each side wall 60 would provide a side cutter 61 mounted on the front edge of the wall, as seen in FIG. 1, which would, like the edge 44 of blade 42 act as a cutting surface. The edge 61 would be welded to the front edge of the side wall 60, and would be of hardened steel or the like material.
FIGS. 2 through 6 illustrate in detail the mounting system which has been heretofore described, and the additional mounting system which is unique to the apparatus. As illustrated, for example in FIG. 5, the side walls 60, are mounted to the blade 42 via a mounting plate 67 which would in turn bolting engage to blade 42. As illustrated, this is accomplished by a first elongated mounting slot 93 which would engage a first transverse mounting slot 95 on blade 42. There would be further provided a pair of mounting slots 97, 99 on plate 67 to accommodate a pair of bolts 101 through a second transverse slot 103 of blade 42. Blade 42 may have additional transverse slots as illustrated in FIG. 10. In this manner the bolting between the mounting plate 67 and the blade 42, through the sloted openings allows the blade to be accomodated onto a variety of widths of excavating buckets. That is, once the blade is positioned via the teeth 30 of the bucket fitted into receiving space 56, the side walls would be fitted against the edge of the bucket, and once the alignment is complete, the bolts 101 are tightened, and the side walls are in place. Further, it should be noted that the side walls are further supported by a pair of gusset plates 64 and 65 mounted to plate 67, so as to help support the side walls 60. This means is clearly shown in the figures, particularly FIGS. 4 through 7.
As seen in FIG. 5, there is illustrated an additional connection means which comprises a generally elongated mounting rod 70, extending from each gusset plate 64, positioned on each side of the blade 42, and each side wall 14, 16 of bucket 12. In operation, the mounting rods 70 provide stability, yet provide a means to allow the blades to be positioned upon various sizes of buckets 12, and provide for some movement between the connections. Overall, as seen in FIG. 4, the mounting rod 70 in reality comprises a series of inter-working parts. There is provided a first upper section or outer housing 72 and a second lower section 74, with the body 75 of section 74 moving into the space 77 defined by housing 72. Further there is provided a mounting means, or padeeye 80, having a ball joint 82, at each end to define the entire mounting system 70. One padeye 80 would be secured to the lower housing 74 through welding of the like and would include a ball joint 82 in padeeye 80 so that a gusset pin 84 secured to the gusset plate 64, as seen in FIG. 6A, could be inserted through the port 83 in ball joint 82 and securely mounted to padeye 80. The upper housing 72 would likewise have padeye 80 mounted on its end, housing a ball joint 82 for inserting a mounting bolt 84A through port 83 in ball joint 82 and securely mounting the upper end of the rod to the walls 14, 16 of bucket 12. As seen in FIG. 8, the walls 14, 16 of bucket 12 would be reinforced with plates 19, with the head 84B of bolt 84A recessed within plate 19 to avoid contact with material in bucket 12.
However, in this case, padeye 80 would be able to rotate free of body section 72. The means for accomplishing this would be a post 85 welded or threaded onto padeye 80, and extending through the upper wall 81 of body 72. The second end of post 85 would be attached to a base member 87 would be positioned within the space 77 of housing 72, and would rotate freely within space 77, with post 85 serving as the axis of rotation. To reduce the wear between the upper wall 81 of body 72 and base member 87 there would be provided a wear bushing 89, of nylon or the like material, to provide more wear and easier rotation.
Of course, the upper housing 72 must be engaged to lower housing 74. The means for accomplishing this is provided by a central bolt member 76 extending down the length of upper body 72, with the end of the bolt secured within body 72 by a mounting bushing 91 mounted onto the wall of the body 72 via welding or the like. The bolt 76 would thread into a nut 93 welded into the housing space within lower housing 74, so that rotation of housing 72 would thread bolt 76 into nut 93, to reduce or increase the length of the mounting sleeve as required, yet allow the two padeyes 80 mounted on each end to remain securely attached to the gusset plate 64 and to the wall 16 of bucket 12.
Following the mounting procedure, once each end is secured in place, the free rotation of the housing 72 would impart rotation to bolt 76 within threaded port 78, and depending on the rotation of housing 72, would provide for the extension of the retraction of the overall length of rod 70. This is necessary, since the blade 42 may be mounted to various size buckets, and would require that the rod 70 have the capability to retract and extend as required. It should be noted, also, that the configuration of the housing 72 around the threaded bolt 76 provides for protection of the bolt from outside knocks of the like. Further, since each padeye 80 includes a ball joint 82, this allows for some swiveling movement of the mounting rod 70 of the between the blade 42 and the bucket 12, as seen in phantom view in FIG. 8, rather than having a rigid attachment, which allows for accomodating varied bucket widths. As seen further in the figures, once the rod 70 has been properly adjusted, there is provided a set screw 90 in the wall of housing 72, so that when secured, prevents further rotation of housing 72, until desired. Further is provided a grease fitting 92 on the wall of housing 42 so that grease may be injected in to the housing to prevent rusting or corrosion of the internal connections between the body portions of rod 70.
In most cases, when the blade 42 is secured to the bucket 12, the walls 14, 16 of bucket 12 will be accommodated with holes so that the rod 70 may be secured therethrough. However, in certain instances, a hole may have to be drilled into a bucket wall to accommodate the mounting bolt, and when this is done, the hole is prepared to accommodate the mounting bolt for proper installation.
Glossary of terms
apparatus 10
bucket 12
sidewalls 14, 16
front edges 17
reinforcing plates 19
base portion is
upright portion 20
floor 22
upper portion 24
arms 26
teeth members 30
front edge 32
body portion 34
beveled edge 36
point 38
space 40
blade 42
upper surface 43
front edge 44
under surface 46
mounting system 50
lip 51
upper mounting plate 52
opening 53
mounting members 54
support gussets 55
receiving space 56
side walls 60
side cutter 6
gusset plates 64, 65
mounting plate 67
mounting rod 70
outer housing 72
lower section 74
body 75
space 77
threaded bolt 76
threaded port 78
padeye 80
ball joint 82
retaining piston 82A
port 83
gusset pin 84
bolt 84A
head 84B
nut 84C
post 85
base member 87
wear bushing 89
set screw 90
mounting bushing 91
grease fitting 92
nut 93
first transverse mounting slot 95
mounting slots 97, 99
bolts 101
second transverse mounting slot 103
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | An improved excavating bucket, having a pair of sidewalls, a rear wall, a floor portion and an open front portion for receiving material thereinto; a plurality of teeth members secured to the floor portion for digging into the material to be excavated; a finishing blade mounted to the bucket, the blade extending across a width greater than the width of the bucket opening, and having a forward edge for scraping; a raised channel formed on the upper face of the blade for engaging a plurality of the teeth members; sidewall members extending from the outer edges of the blade for engaging the wall of the bucket, for defining an uninterrupted travelling space for material into the bucket; and adjustable support rods able to be swivelly positioned between the blade and the bucket sidewalls to stabilize the blade mounted on the bucket. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to the production of pile fabric on a loom having a pile-warp beam, a ground-warp beam, and a batten the stroke of which during operation is periodically decreased from the value corresponding to a full stroke of the batten by a value for partial strokes which is referred to as the pre-beating distance.
In the manufacture of pile fabric, it is necessary, in order to obtain goods of good quality, that the quantity of pile-warp yarns fed and the pile-warp tension in the shed be as constant as possible. This requirement is imposed by the fact that variations in the ground-warp tension affect the pre-beating distance, which results in irregularities in the height of the pile.
The influence of changes in the ground-warp tension on the height of the pile results from the fact that with an increase in the tension of the ground warp, the so-called cloth advance, that is the movement of the fell of the cloth upon the backward swinging of the batten from its defined position in the direction towards the batten, becomes smaller so that the following pre-beating distance becomes greater. This in its turn leads to a greater height of pile.
The closest prior art known to the inventor is U.S. Pat. No. 4,112,981.
SUMMARY OF THE INVENTION
The present invention provides a process by the use of which the pile height remains constant even upon changes in the tension of the ground warp.
This purpose is achieved, in accordance with the invention, in the manner that during the weaving process the pre-beating distance is reduced or increased upon changes in the pile-warp tension.
It has been found that changes in the pile-warp tension are a suitable criterion for indicating irregularities in the height of the pile due to changes in the ground-warp tension, since the effect described above that the height of pile increases with an increase in the tension of the pile warp leads to the result that with a constant length of conveyance of the pile-warp yarns, the pile-warp tension increases.
The invention furthermore concerns a loom for the carrying out of said process, having a feed roller for withdrawing the pile-warp yarns from the pile-warp beam and a batten drive device which comprises a control mechanism for shifting the position of the beating-up position of the reed.
This loom is characterized by the fact that there is provided a control means which is connected to the control mechanism and can be activated upon changes of the pile-warp tension by a predetermined minimum value, the control mechanism being acted on by said control means in order to change the pre-beating distance.
In a preferred embodiment, the loom is characterized by the fact that the control means has a detector for detecting changes in the pile-warp tension, a motor which can be controlled by the detector, and a displacement means for changing the pre-beating distance which can be driven by the motor and is connected to the control mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described below in further detail on the basis of an illustrative example and the figures of the drawing in which:
FIGS. 1 and 2 are each a schematic cross-section through a terry loom for two different beating-up positions of the reed;
FIGS. 3 and 4 each shows details of FIGS. 1 and 2 respectively on a larger scale; and
FIG. 5 shows a further detail of FIGS. 1 and 2, showing diagrammatically a detector operatively connected to a motor for detecting changes in pile-warp tension.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1 and 2 there is shown a terry loom whose reed is in full beat-up position in FIG. 1 and in partial beat-up position in FIG. 2. FIGS. 3 and 4 show on a larger scale a view of the batten path shortening mechanism for the fully beat-up position (FIG. 3) and for the partial beat-up position (FIG. 4). FIG. 5 shows diagrammatically the device for changing the pre-beating distance as a function of changes in the pile-warp tension.
The terry loom shown in the figures has a machine frame with two sidewalls, of which the right side wall 1 is diagrammatically shown. Between the side walls there are arranged a ground-warp beam 2 with a spreading roller 3 for the ground warp 4, a pile-warp beam 5 with a feed roller 6 and a floating roller 7 for the pile warp 8, a batten shaft 9, a breast bar 10, a spreading roller 11, a take-up roller 12, a guide roller 13, and a cloth beam 14. The yarns of the ground warp 4 and of the pile warp 8 are fed via shed-forming heddles 15, by which they are subjected to shedding, to the fell of the cloth 16. The cloth formed is designated 17 and is wound on cloth beam 14 during operation of the loom. On the batten shaft 9 there are swingably mounted the batten tube 34 which bears the batten 19 with the reed 18, and a batten lever 20 which is rotatably connected with the batten tube 34.
The drive of the batten lever 20 will now be described by reference to FIGS. 3 and 4: Two cams 22 are firmly mounted on a drive shaft 21 which can be driven by a motor in the direction indicated by the arrow A. Associated with the cams 22 is a roller lever 23 which is turnably mounted on the batten shaft 9 and on which two rollers 24 turnable on the face of cams 22 are rotatably supported. The roller lever 23 is provided at its left end, as seen in the figures, with a supporting shaft 25 on which there is mounted a first lever 26. The free end of the first lever 26 is clamped onto a shaft 27 on which there are turnably mounted the one ends of a second double-sided lever 28. The other ends of the second double-sided lever 28 are pivotally connected via a shaft 29 with the batten lever 20. On the shaft 21 which connects the first lever 26 with the second lever 28, separate slide blocks 30 are turnably mounted on both sides of the said levers. The first lever 26 and the second lever 28 together form a toggle joint, the angle of bend of which can be controlled via the slide blocks 30.
Operably associated with the slide blocks 30 is a double-sided control lever 31. Each side of the control lever 31 is provided with a separate guide groove 32 having the shape of a circular arc for the slide blocks 30. The control lever 31 is swingably supported around two bearing pins 33 arranged on both sides and it is pivoted at its right-hand upper end, as seen in the figures, to a control rod 35.
The roller lever 23, the toggle lever formed by the first lever 26 and the second lever 28, and the batten lever 20 together form a link quadrilateral, the angle of bend of the toggle joint representing a characteristic value for the size of the stroke of the batten 19. The articulation points of the said link-quadrilateral are established by the batten shaft 9, the bearing shaft 25, the shaft 27, and the shaft 29. As is known, when producing terry cloth one operates in the manner that, within a three-pick or four-pick cycle, a full beating takes place for every two or three partial beating movements respectively of the reed, and upon this full beating the three or four picks are finally beaten up and the loops formed by the pushing together of the partially beaten-up filling yarns.
The periodic shortenings of the batten stroke which are necessary for the partial beatings are obtained by displacement of the angle of bend of the toggle joint formed by the first lever 26 and the second lever 28 by changing the geometry of movement of the said link quadrilateral. This is done by the control lever 31 via the slide blocks 30. When the batten 19 is in its rear backward-swung position, the toggle joint is extended and the link quadrilateral has been converted into a link triangle. The pivot point of the control lever 31, i.e. the axes of the bearing pins 33 on the two sides, coincides at this moment with the axis of the shaft 27 which forms the pivot point of the toggle joint.
In its backward-swung position, the batten 19 stops. At this time of stop, the displacement of the control lever 31 takes place. If the next beating is to be a full beat-up, then the control lever 31 is swung in clockwise direction into the position shown in FIG. 3. In this way, the pivot point of the control lever 31 and the pivot point of the toggle joint formed by the first lever 26 and the second lever 28 lie on a common circular arc B, shown in dash-dot line in FIG. 3, having its center point in the axis of the batten shaft 9 and therefore in the center of swing. The pivot point of the shaft 29 is associated via the batten lever 20 with a different lever-arm length with the same center of swing. Thus, the toggle joint remains in its extended position for the entire full-beating cycle.
If the next beat-up is to be a partial beating in accordance with FIG. 4, then the control lever 31 is swung in counterclockwise direction by an angle which depends on the pre-beating distance and therefore on the distance on the line of symmetry M of the shed between the batten position for full beating and that for partial beating. This position of the control lever 31 determines a new central path C of the curve formed by the guide groove 32, which curve no longer has its center in the center of swing and therefore in the axis of the batten shaft 9.
In this way, the turning point of the toggle joint during the swinging movement produced by the roller lever 23 is forced, via the shaft 27 turnably supported in the slide blocks 30, to slide along the new curved path C and to produce, in positive manner, a link quadrilateral from the link triangle.
Upon this outward bending movement of the toggle joint formed by the first lever 26 and the second lever 28, the bearing places of the slide blocks 30 on the shaft 27 serve as support points for maintaining equilibrium for the force of reaction resulting from the force parallelogram. This force of reaction acts on lever arms of different length. Depending on the position of the pivot point of the toggle joint, the force of reaction imparts to the control lever 31 a torque of varying amount and direction during the movement cycle. This torque is taken up, in accordance with FIGS. 1 and 2, by a stop which comprises a stop jaw 36, said stop being done away with in the backward-swung position of the batten 19 by stop eccentrics 37, 37' via a roller 38 and a spring bar 39.
The relative position of rest of the batten 19 during the changes in position of the control lever 31 brings it about that upon these changes in position only the inertia forces of the parts participating in the change in position are present throughout the entire drive system for the batten 19. This fact is of particularly great importance for looms in which the insertion of the filling, which takes place during the position of rest of the batten 19, is effected with gripper heads which lie on the batten path and are fastened to bars or flexible ribbons. Due to the extended position of the toggle joint upon full beating, no forces of reaction resulting from inertia or drive forces and acting on the control or stop mechanism occur either.
In accordance with FIGS. 1 and 2, the actuating of the control lever 31 is effected by control cams 40, 40' via a control rod 41 of adjustable lift, a bell-crank lever 42 supported on a pivot axis which is fixed to the machine, and the control rod 35. Of the control cams 40, 40' as well as of the stop cams 37, 37' one cam in each case is intended for three-pick operation and one for four-pick operation. In order to obtain full ability of return of the various control movements with the batten 19 stationary in case of break of the filling, the drive of the cam-actuated stop jaw 36 and the cam drive for the control lever 31, both of which are arranged in the construction above the machine wall 1, are derived from a returnable driven auxiliary shaft 43.
For this purpose, a rocker 44 is swingably supported on the auxiliary shaft 43 and three intermediate gear wheels 45, 46, and 47 are rotatably supported in it. The lowermost gear wheel 45 is in engagement with a gear wheel 48 which is mounted fixed on the auxiliary shaft 43 and, via the gear wheel 46, drives the gear wheel 47 which is connected for rotation with the latter. The gear wheel 47 is in engagement with a driven gear wheel 49, 49' connected for rotation with the control cam 40, 40' and the direction of rotation of which is indicated by an arrow D. The driven gear wheel 49 or 49' and corresponding control cam 40 or 40' and stop cam 37 or 37' flanged onto said gear wheel are pushed over a fixed shaft 50. In order to change from three-pick weave to four-pick weave and vice versa, the rocker 44 is swung out, whereupon control cam 40 or 40' with stop cam 37, 37' and driven gear wheel 49 or 49' can be changed. In case of three-pick weaving, the driven gear wheel 49 travels at one-third of the speed of rotation of the main shaft, while in the case of four-pick weaving it travels at one-fourth the speed thereof.
The angle of swing produced by the control cam 40 or 40' is transmitted to a thrust crank 53 which is connectedly fixed for rotation with a hollow shaft 51 and a roller lever 52. By preselection of variable lever-arm ratios on the driving swivel arm of the thrust crank 53, a variable working stroke is produced as a function of the pre-beating distance desired and is transmitted to the batten-path shortening control consisting of the control rod 41, the bell crank lever 42, and the control rod 35. The lever-arm ratio is in this connection adjusted to the larger of two desired heights of pile. For the production of the shorter height of pile, the roller lever 52 is prevented by an inward-swingable first underlaying finger 54 from following the control cam 40 or 40' entirely into its valley, i.e. the roller 55 of the roller lever 52, at a given portion of the circumference of the control cam 40 or 40', lifts off from the latter. In this way the thrust crank 53 is transmitted only a part of the angle of swing.
By a second, longer underlaying finger 56 the roller 55 can be permanently raised from the control cam 40, 40' so that upon the inward swing of this underlaying finger full stops are always obtained for the batten 19 and therefore a smoother fabric is produced. Upon the production of terry-cloth with the larger pile height, of course, neither of the two underlaying fingers 54 or 56 is swung inward. For the pressing of the roller 55 against the control cam 40, 40' there is provided a compression spring 57. The control of the inward swinging of the underlaying fingers 54 and 56 is effected by the shed-forming machine or, when using a drum treadle, by the central function-control device.
FIG. 5 shows diagrammatically the feed roller 6, the floating roller 7 and the control rod 41 (FIGS. 1, 2). Feed and floating rollers 6, 7 are fastened to the machine frame in the manner described in U.S. Pat. No. 4,112,981 issued Sept. 12, 1978, which is made a part of this application by reference. The feed roller 6 consists of a support roller 58 which is rigidly connected at its one end to a gear wheel 59 and consists of a jacket tube 61 of light metal or plastic. The gear wheel 59 is driven, stepwise or continuously, from the pile switch mechanism (not shown) via a toothed belt 60. The jacket tube 61 is connected by spokes 65 with a hub 75 which is rotatably supported on the support roller 58 and is provided on its outer surface with a driving covering 62, preferably a plush covering.
On the support roller 58 there is fastened a pin 63 which extends outward through its cylindrical wall. On this pin 63 there acts the one end of a spring 64 whose other end is fastened to the jacket tube 61, as shown in the drawing, on a threaded spindle 76 adjustably supported in a spoke 65. The spring 64 counteracts the pile-warp tension and assures the transmission of force from the support roller 58 to the jacket tube 61 so that the latter participates in the turning movements of the support roller 58 for the feeding of the pile warp yarns 8.
The strength of the spring 64 thus determines the tension of the pile warp. Since this spring strength is adjustable via the threaded spindle 76, operation is considerably facilitated, since now, in the case of a new article, it is merely necessary for the feed length of the pile warp yarns and their correct tension to be adjusted while previously pre-beating distance and length of feed had to be adapted to each other by a tedious procedure. This adaptation is now effected automatically.
On the inside of the jacket tube 61 there are mounted two stops 66 and 67 which bear electric switches 68 and 69 respectively extending into the path of movement of the pin 63. The switches 68 and 69 are operatively connected via lines 70, 71 with a motor means 72 drivable from a source of current not shown. The motor means 72 drives a threaded spindle 73 which is supported in a nut 74 pivotally mounted on the control rod 41. Since the motor means 72 is firmly attached to the loom frame, a turning movement of the threaded spindle 73 means a displacement of the nut 74 and thus a displacement of the upper end of the control rod 41 in the guide groove of the thrust crank 53 (FIGS. 1, 2). The latter effects a displacement of the prebeating distance. The motor means 72 contains a time member (not shown) in the form of a counter by which the rotation of the threaded spindle 73 is disconnected after an adjustable number of revolutions or after a given period of time.
As can be noted from FIG. 5, in case of too high a tension of the pile warp, the jacket tube 61 is turned by the pile warp yarns 8 in counterclockwise direction relative to the support roller 58 against the force of the spring 64. As a result, the switch 69 comes into contact with the pin 63 and is actuated. In this way, a signal arrives via the line 71 at the motor means 72 which drives the threaded spindle 73 in one direction. By the rotation of the threaded spindle 73, the nut 74 is moved to the right, together with the control rod 41 (FIGS. 1, 2), which results in shortening of the pre-beating distance. In the event of too low a tension of the pile warp, the switch 68 is actuated and the threaded spindle is driven in the other direction, as a result of which nut 74 and control rod 41 are moved to the left and the pre-stroke distance is lengthened.
It will be appreciated that switches 68 and 69 can be actuatable by mechanical contact or they can be developed as proximity switches. Similarly, the determination of the change of the pile-warp tension could be effected in some other manner by other types of detection means. Thus, for instance, a fixed driver, in the manner of the pin 63, could be fastened to the support roller 58 and a resilient driver, associated with it, could be fastened to the jacket tube 61. The resilient driver could bear a signal arm which would extend into the space between two switches fastened to the support roller 58.
It would also be possible to connect the jacket tube 61 firmly to the support roller 58 and to guide the pile-warp yarns 8 behind the feed roller 6 over a resiliently supported swing roller and detect changes of the pile-warp tension on the basis of swinging movements of this swing roller. This swing roller could be supported by arms mounted on the common shaft of support roller 58 and jacket tube 61 or arms supported on the shaft of the floating roller 7. The swinging movement of these arms could be detected.
It will be understood that the drive device for the batten comprises a control mechanism for shifting the beat-up position of the reed, there being a control means operatively connected to the control mechanism so that control means is activated upon a change of the pile-warp tension by a predetermined minimum value, by which means the control mechanism can be acted on in order to change the pre-beating distance.
Although the invention is described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The production of pile fabrics in which the stroke of the batten of a loom during operation is periodically decreased from the value corresponding to a full stroke of the batten by a value for partial strokes which is referred to as the pre-beating distance. | 3 |
TECHICAL FIELD
[0001] This invention relates generally to scripting simple object access protocol (SOAP) commands using extensible markup language (XML) and to providing the resulting XML script to a device for execution.
BACKGROUND
[0002] An apparatus may contain an embedded controller or agent software to monitor and control its operation. Any type of apparatus may have an embedded controller or agent including, but not limited to, home appliances, office equipment, medical devices, and industrial tools. Other examples include robots, blood analyzers, multifunction copiers, and air conditioners.
[0003] Embedded devices are often connected to an internal network, such as a local area network (LAN), with an interface to the Internet. Other devices on the internet network may communicate with an embedded device over the internet network. However, the embedded device is not generally addressable from the Internet. To address this problem, the embedded device may initiate communications with an addressable external device. That is, the embedded device may access the external device (e.g., a server) periodically to obtain necessary data.
[0004] SOAP is a standard for encoding function calls, such as remote procedure calls (RPCs), in XML. SOAP defines rules, i.e., a syntax, for encoding the function calls in XML. The body of a SOAP command is defined, at its start, by <SOAP-ENV:BODY> and, at its end, by </SOAP-ENV:BODY>. Code in between these two commands includes the function to be performed by the SOAP command. A SOAP command may include other data as well, such as header information.
SUMMARY
[0005] Heretofore, SOAP commands were only available as individual, discrete commands. This is impractical for device-initiated communication, particularly if the device is unaware of any timing issues relating to execution of the SOAP commands. The invention therefore scripts one or more SOAP commands in XML and provides the XML script to a device, such as an embedded controller, for execution. The XML script is executed by the embedded controller, much like a computer program, to control execution of the SOAP commands. For example, timing and sequence of execution of the SOAP commands may be specified in the XML script.
[0006] The invention also defines variables in the XML script, which may be passed to and from the SOAP commands. This facilitates the combination of SOAP commands in XML script and provides an advantage over the use of traditional SOAP commands, which are limited to passing “hard-coded” numerical values (i.e., non-variables).
[0007] In general, in one aspect, the invention is directed to a computer-implemented system for processing a simple object access protocol (SOAP) command. The system includes interpreting an XML script to perform a function contained in the XML script, the XML script containing the SOAP command, parsing the SOAP command from the XML script, and passing the SOAP command to a SOAP interpreter for execution. This aspect of the invention may include one or more of the following features.
[0008] Plural SOAP commands may be contained in the XML script. The plural SOAP commands may be passed to the SOAP interpreter. The plural SOAP commands may be executed in a sequence specified by the XML script. At least one of an argument and a return value may be received from the SOAP command following execution of the SOAP command. The argument may be stored as a variable in the XML script.
[0009] The XML script may declare a variable. A value of the variable may be passed as an argument to the SOAP command prior to executing the SOAP command. The function may be a conditional statement. The conditional statement may be an If-Then statement or an If-Then-Else statement. The function may be a control statement that affects a sequence of execution of the XML script and/or the SOAP command. The control statement may be a loop. The function may be an exception handler that affects a sequence of execution of the XML script and/or the SOAP command when an error condition exists. The function may be a statement that controls relative or absolute time to execute the SOAP command. Parsing may be performed by an XML interpreter and executing may be performed by the SOAP interpreter. The XML interpreter may pass the SOAP command to the SOAP interpreter and the SOAP interpreter may pass an output of the SOAP command to the XML interpreter.
[0010] In general, in another aspect, the invention is directed to a computer-implemented system for generating extensible markup language (XML) script that contains a simple object access protocol (SOAP) command. The system includes receiving code that defines a function and the SOAP command and translating the code to XML script that performs the function and contains the SOAP command. This aspect of the invention may include one or more of the following features.
[0011] The XML script may be provided to a device. The device may include a controller that executes the XML script. The code may contain plural SOAP commands and functions. The XML script may contain the plural SOAP commands and functions. The XML script may declare a variable. A value of the variable value may be passed as an argument to the SOAP command in the XML script.
[0012] The function may be a conditional statement. The conditional statement may be an If-Then statement or an If-Then-Else statement. The function may be a control statement that affects a sequence of execution of the XML script and/or the SOAP command. The control statement may be a loop. The function may be an exception handler that that affects a sequence of execution of the XML script and/or the SOAP command when an error condition exists. The function may be a statement that controls a relative or absolute time to execute the SOAP command.
[0013] Other features and advantages of the invention will become apparent from the following description, including the claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block diagram of a network containing a server and a device having an embedded controller;
[0015] FIG. 2 is a flowchart showing a process for translating human-readable code into XML script;
[0016] FIG. 3 is a flowchart showing a process by which the embedded controller retrieves XML script for the device from the server; and
[0017] FIG. 4 is a flowchart showing a process by which the embedded controller executes the XML script.
DESCRIPTION
[0018] FIG. 1 shows a network 10 . Network 10 includes a device 11 containing an embedded controller 17 . Device 11 is any type of apparatus or system having functions that are monitored and controlled by embedded controller 17 .
[0019] Device 11 is connected to an internal network 12 , such as a LAN. A router or modem 14 couples internal network 12 to an external network 15 , such as the Internet/World Wide Web (Web). External network 15 runs TCP/IP (Transmission Control Protocol/Internet Protocol) or some other suitable protocol. Network connections are via Ethernet, telephone line, wireless, or other transmission media.
[0020] External network 15 contains a server 19 , which is a computer or any other processing device. Server 19 communicates with embedded controller 17 over external network 15 and internal network 12 . Embedded controller 17 has a local IP (Internet Protocol) address that can be resolved within internal network 12 . However, this local IP address may not be recognizable by devices or external network 15 , such as server 19 . As such, server 19 may not be able to directly address device 11 .
[0000] Embedded Controller
[0021] Embedded controller 17 runs software 20 , which includes Web client application 21 and operating software 22 . Web client application 21 includes a TCP/IP protocol stack that allows embedded controller 17 to communicate over external network 15 . Device operating software 22 provides an interface between Web client application 21 and a database 24 in memory 25 . Through device operating software 22 , embedded controller 17 retrieves data stored in database 24 and stores data in database 24 .
[0022] Software 20 also includes an XML interpreter 23 and a SOAP interpreter 26 . XML interpreter 23 is a module that receives XML script, parses the script, and performs the functions identified by the script. As background, XML is a self-describing computer language, meaning that fields in XML code identify variables and their values in the XML code. For example, a “data” field is delineated by “<data>” to indicate the start of the field and “</data>” to indicate the end of the field. XML is used because it can be generated, parsed and understood relatively easily.
[0023] Among the functions in the XML script may be an instruction to identify a SOAP command and to pass the SOAP command to SOAP interpreter 26 for processing. An example of another function includes a statement that controls relative or absolute time to execute the SOAP command. SOAP enterpreter 26 receives SOAP commands from XML interpreter 23 and executes those commands. Examples of SOAP commands that can be executed by the embedded controller or agent include setting the value of a variable, uploading or downloading a file, restarting the software, or any action specific to the apparatus.
[0024] Database 24 stores data, such as operational parameters, XML script, and identification information for the instance of device 11 . What is meant by “instance” is the specific identity of device 11 as distinguished from other identical devices. The identification information stored in database 24 identifies the instance of device 11 . This identification information may include data identifying the type of the device, a common (or “friendly”) name for the device, the manufacturer of the device, the model name of the device, the model number of the device, the serial number of the device, or a universal unique identifier (UUID) for the device.
[0025] The device type is the name of the device. The common name of the device is how the device is known in the vernacular, e.g., “television”. The manufacturer identifies the manufacturer of the device, e.g., Sony®. The model name identifies the particular model of the device, e.g., Wega®. The model number identifies the model number of the device, e.g., XBR400®. The serial number identifies the serial number of a particular instance of the device, e.g., 53266D. The UUID is a universal identifier for the instance of the device, e.g., 4A89EA70-73B4-11d4-80DF-0050DAB7BAC5. Of the data shown above, generally only the serial number and the UUID are unique to the instance of device 11 .
[0026] The identification data stored in database 24 is used by embedded controller 17 to retrieve XML script specific to the instance of device 11 (or for a particular type of device 11 ) from server 19 . A device-initiated process for retrieving the XML script is described below.
[0000] Server
[0027] Server 19 is a computer that runs an HTTP (Hypertext Transfer Protocol) Web server computer program. Server 19 includes a controller 27 , such as a microprocessor, for executing software to perform the functions described below. To avoid confusion in terminology, the following reads as though those functions are performed by server 19 , even though software in controller 27 of server 19 performs the functions.
[0028] Server 19 executes Web server software 29 to communicate over external network 15 . Web server software 29 also hosts a Web page associated with device 11 . The Web page (not shown) is displayed on computer 33 of a user, such as the owner of device 11 , who may select some actions to be sent to the device. For example, a remote operator may want to update three operational variables, which requires three SOAP commands. These three SOAP commands are wrapped in an XML script that executes the commands as a single operation. The XML script, along with any input updated operational parameters (if desired) are transmitted to Web server software 29 over external network 15 . Web server software 29 stores the XML script in database 30 of memory 31 . An example of a process for updating operational parameters is described in U.S. patent application Ser. No. 09/667,737, filed Sep. 22, 2000, the contents of which are incorporated into this application by reference as if set fourth herein in full.
[0029] Web server software 29 stores and retrieves SML script from database 30 using application logic 32 . Application logic 32 is software for accessing database 30 using Java servlets and a JDBC (Java Data Base Connectivity) database driver. The XML script can be stored in database 30 individually or as part of a configuration file for an instance of device 11 .
[0000] Computer
[0030] Computer 33 is personal computer (PC) or other machine that includes a processor 36 , a memory 37 , and a storage medium 38 (see view 55 ). Storage medium 38 stores computer programs 39 , which are executed by processor 36 out of memory 37 . Computer programs 39 include a Web client application 43 containing a TCP/IP protocol stack for communicating over the Internet, a Web browser 44 such as Microsoft® Internet Explorer® for accessing Web pages, an operating system (OS) 45 such as Microsoft® Windows98®, and executable instructions 45 for implementing process 50 , which is shown in FIG. 2 .
[0031] Process 50 generates XML script containing one or more SOAP commands from user-generated code provided to computer 33 . The code may be input by the user via a graphical user interface (GUI) (not shown), for example, or it may be retrieved from a storage medium or over network 15 .
[0032] The code has a syntax that can be understood and interpreted by instructions 46 . For example, the code may be a commonly-understood computer language, such as BASIC or “C”, or a form of pseudo-code specific to the invention. The code defines functions, such as conditional statements (e.g., If-Then or If-Then-Else statements), control statements (e.g., do While or do Until loops), or exception handlers, meaning fail-safe mechanisms that are triggered in the code in the event that an instruction in the code fails. The functions affect the sequence of execution of the resulting XML code and/or SOAP commands.
[0033] An example of user-generated C/C++ code is set forth below:
int local = 8; int total = 0; while ( total < 10 ) { total = SomeFunction(total); AnotherFunction(local); }
This code initializes integer variables “local” and “total” to values of “8” and “0” respectively. The code includes a “While” loop, meaning that the loop between the brackets “{}” is continually executed while the value of total is less than “10”, whereafter processing within the loop is discontinued. Within the loop, the value of “total” is set equal to the result of a SOAP command called “SomeFunction” processing the previous value of “total” and another SOAP command called “AnotherFunction” processing “local”.
[0034] Process 50 receives ( 201 ) code, such as that shown above, that defines one or more functions (e.g., a “While” loop) and one or more SOAP commands (e.g., “SomeFunction” and “AnotherFunction”). Process 50 translates ( 202 ) the code to XML script that, when interpreted, performs the functions and contains the SOAP commands. To perform the translation, process 50 may compile the code, interpret the functions in the compiled code, and generate appropriate XML script from the compiled code. An appropriate compiler may be included within instructions 46 for this purpose. The format of the SOAP commands may be static and known to the compiler, or the format may be determined dynamically from a WSDL (Web Services Description Language) document. WSDL is a standard for describing SOAP commands. WSDL is itself an XML document that can be interpreted automatically. WSDL defines the set of functions available and the format of each of the SOAP commands.
[0035] WSDL usually describes the functionality for a particular device or Web service. By reading WSDL, a program can display functions to a user, then create SOAP command(s) for the function(s) selected by the user. By way of example, there may be one thousand devices, all with individual settings, and it is desired to set all of the devices to 6% lower power usage. Using traditional SOAP commands, the server must be able to address each device, obtain each device's current setting, calculate 94% of its value, then write that new value back to each device, all through issuing individual SOAP commands. Using a SOAP script, the same script can be sent to all of the devices because the variable is evaluated locally at each device. As the population of monitored devices grows, this kind of distributed processing becomes more useful.
[0036] Continuing with the example set forth above, process 50 translates ( 202 ) the code into the following XML script:
<Root> <Variables> <local type=“integer”>8</local> <total type=“integer”>0</total> </Variables> <Script> <While conditions=“total < 10”> <SOAP-ENV:Body> <SomeFunction> <Count>total</Count> </SomeFunction> </SOAP-ENV:Body> <Return variable=“total”/> <SOAP-ENV:Body> <AnotherFunction> <Input>local</Input> </AnotherFunction> </SOAP-ENV:Body> </While> </Script> </Root>
The XML script contains the same functions and SOAP commands as the original C/C++ code input by the user. For example, the “While” loop is expressed as
<While condition=“total< 10”> and </While>
[0037] and the SOAP commands are expressed as
<SOAP-ENV:Body> <SomeFunction> <Count>total</Count> </SomeFunction> </SOAP-ENV:Body> and <SOAP-ENV:Body> <AnotherFunction> <Input>local</Input> </AnotherFunction> </SOAP-ENV:Body>
The expression “<Return variable=“total”/>” returns the value of the variable “total” to the XML script. Thus, the output of the SOAP command may be passed back to the XML script as an argument in the SOAP command and used as a variable in the XML script. Also, the XML script may be written so that a variable, such as “total”, is passed as an argument to a SOAP command.
[0038] An example of XML script containing a conditional “IF” statement is set forth in Appendix A attached hereto. An example of XML script containing an exception handler is set forth in Appendix B attached hereto.
[0039] After the code has been translated ( 202 ) to XML script, process 50 provides ( 203 ) the XML script to server 19 over network 15 . Process 50 may send the XML script to server 19 through a Web interface, along with identification information that specifies the instance of device 11 for which the XML script is intended. Web server software 29 on server 19 receives the XML script over network 15 and application logic 32 stores the XML script in database 30 , along with its associated identification information.
[0000] Device-Initiated Retrieval Of The XML Script
[0040] Embedded controller 17 executes software 20 to retrieve the XML script intended for device 11 from remote server 19 . In response, server 19 executes software 34 to send the XML script to embedded controller 17 . FIG. 3 shows these processes in detail. The left half of FIG. 3 , titled “Embedded Controller” shows process 40 performed by embedded controller 17 , and the right half of FIG. 3 , titled, “Server”, shows process 41 performed by server 19 .
[0041] Process 40 generates and sends ( 301 ) a command to server 19 . The command, or a modified version thereof, is sent by embedded controller 17 to server 19 periodically. It is through this command that embedded controller 17 polls server 19 to determine if there is any new/updated XML script for device 11 on server 19 .
[0042] The command includes XML data identifying device 11 . The data identifies the specific instance of device 11 and may include a device type field and one or both of a device serial number field and a device UUID. The command may also include a common name field, a manufacturer name field, a model name field, and a model number field, which specify the information set forth above for the device.
[0043] The command may be either an HTTP Get command or an HTTP post command. The data included in those commands is similar, with the difference being that the HTTP GET command retrieves a document, such as a file containing the XML script, and the HTTP POST command retrieves information, such as the XML script itself.
[0044] Process 41 (in server 19 ) receives ( 302 ) the HTTP command from embedded controller 17 . Process 41 identifies the command as either a POST or GET command based on a header, such as “POST/CONTROL HTTP/1.1” (for a POST command), in the command. Process 41 uses an XML parser to parse ( 303 ) the various identifying fields, such as device type, serial number, and UUID, from the command.
[0045] Process 41 identifies ( 304 ) the instance of device 11 based on the information parsed from the command. That is, process 41 uses the device type, serial number, and UUID field information to identify the instance of device 11 .
[0000] If The Command Is A POST Command
[0046] The identification information from the command, in particular the device serial number and/or UUID, is used to search through database 30 for XML script specific to device 11 . Once the appropriate XML script has been identified ( 304 ), process 41 retrieves ( 305 ) that XML script from database 30 using application logic 32 . Process 41 determines if the XML script has been updated since it was last retrieved. This may be done by examining a revision number or date included in a header associated with the XML script. If the XML script has been updated, process 41 adds the updated XML script to the reply portion of POST command and sends ( 306 ) the POST command, with the updated XML script, back to embedded controller 17 .
[0000] If The Command Is A GET Command
[0047] As was the case above with the POST command, the identification information from the command is used to search through database 30 for XML script for the specific instance of device 11 . In particular, the device serial number and/or UUID are used to retrieve ( 305 ) a configuration file that is specific to device 11 . The configuration file contains the XML script for device 11 . Process 41 sends ( 306 ) the configuration file to embedded controller 17 .
[0048] Process 40 receives ( 307 ) the XML script containing one or more SOAP commands from server 19 in response to the HTTP command. Process 40 (in particular Web client application 21 in device 11 ) provides the XML script to XML interpreter 23 , where the XML script is executed.
[0049] Referring to FIG. 4 , a process 52 is shown for executing the XML script in embedded controller 17 . Process 52 is implemented by executable instructions in XML interpreter 23 and SOAP interpreter 26 .
[0050] XML interpreter 23 interprets ( 401 ) the XML script to perform the functions contained therein. For example, if there are any conditional statements, control statements, or exception handlers defined by the XML script, XML interpreter performs those functions on the appropriate commands and variables contained in the XML script.
[0051] During processing, XML interpreter 23 parses ( 402 ) the XML script to identify any SOAP commands contained in the XML script. Identified SOAP commands are passed to SOAP interpreter 26 , which executes ( 403 ) the SOAP commands. Results of the SOAP commands may be passed back to the XML interpreter 23 for further processing. Likewise, variables may be passed from the XML script to the SOAP commands.
[0052] Using XML script in this manner, embedded controller 17 is able to execute multiple SOAP commands in response to a single device-initiated query. Thus, device 11 can perform reconfiguration operations or the like using multiple soap commands without maintaining communication with an external device, such as server 19 , during the reconfiguration process. The XML script can specify (future) times at which the SOAP commands are to be executed, thus providing the device with further control over its own operation. SOAP interpreter 26 implements the SOAP standard to interpret and execute function calls. As more devices and software systems have support for SOAP, device 11 will be able to execute a script that controls multiple devices by calling their SOAP services.
[0000] Architecture
[0053] Processes 40 , 41 , 50 and 52 are not limited to use with the hardware/software configuration of FIG. 1 ; they may find applicability in any computing or processing environment. Processes 40 , 41 , 50 and 52 may be implemented in hardware (e.g., an ASIC {Application-Specific Integrated Circuit} and/or an FPGA {Field Programmable Gate Array}), software, or a combination of hardware and software.
[0054] Processes 40 , 41 , 50 and 52 may be implemented using one or more computer programs executing on programmable computers that each includes a processor, a storage medium readable by the processor (including volatile and non-volatile memory and/or storage elements), at least one input device, and one or more output devices.
[0055] Each such program may be implemented in a high level procedural or object-oriented programming language to communicate with a computer system. Also, the programs can be implemented in assembly or machine language. The language may be a compiled or an interpreted language.
[0056] Each computer program may be stored on a storage medium or device (e.g., CD-ROM, hard disk, or magnetic diskette) that is readable by a general or special purpose programmable computer for configuring and operating the computer when the storage medium or device is read by the computer to perform processes 40 , 41 , 50 and 52 .
[0057] Processes 40 , 41 , 50 and 52 may also be implemented as an article of manufacture, such as one or more machine-readable storage media (e.g., compact or floppy disk), each configured with a computer program, where, upon execution, instructions in the computer program cause a machine (e.g., a computer) to operate in accordance with one or more of processes 40 , 41 , 50 and 52 .
[0058] The invention is not limited to use with the protocols and standards described above. For example, Web server may use Java Servlets, ASP (Active Server Pages), ISAPI (Internet Server Application Programming Interface), or .NET interfaces to communicate with application logic 32 . The HTTP commands sent by embedded controller 17 and/or server 19 are not limited to HTTP GET and POST commands. Any commands and/or requests for requesting and receiving data may be used.
[0059] The invention is not limited to the protocols and architecture described with respect to FIG. 1 . Similarly, the invention is not limited to device-initiated transfers of the XML script. For example, computer 33 may transmit the XML script directly to embedded controller 17 (rather than by way of server 19 ) via e-mail, file transfer protocol (FTP), message queues, or any other type of data transfer mechanism. These other transfer protocols may also be used with device-initiated transfers. Server 19 may generate the XML script and transmit it directly to controller 17 . The XML script may be used on any machine, and is not limited to use with embedded controllers. RPCs other than SOAP calls may be scripted using XML and the resulting XML script may be processed in the manner described herein. SOAP commands other than those described herein may be used. The processes described herein may be implemented using circuitry such as programmable logic, logic gates, a processor, and/or a memory.
[0060] Other embodiments not specifically described herein are also within the scope of the following claims. | A computer-implemented method processes a simple object access protocol (SOAP) command. The method includes interpreting an XML script to perform a function contained in the XML script, the XML script containing the SOAP command, parsing the SOAP command from the XML script, and passing the SOAP command to a SOAP interpreter for execution. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims priority under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 61/870,756, filed Aug. 27, 2013 and titled, “SINGLE OUTPUT CHANNEL ADAPTER FOR CHARGING DURING LAPTOP SLEEP MODE,” which is also hereby incorporated by reference in its entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates to the field of battery charging. More specifically, the present invention relates to device charging using alternative circuits.
BACKGROUND OF THE INVENTION
USB ports on a laptop are used to charge various electronic devices, such as cell phone and music players. Typically, the electrical power is cut-off to the USB port when the laptop goes to a sleep mode or shut down, such that the electronic devices cannot be charged through the USB ports.
FIG. 1 illustrates a typical charging module 100 including an adaptor 102 couples with a laptop 104 . The adaptor 102 can output a voltage V 1 in a battery 106 charging mode. During the charging mode, switch S 1 108 is on “ON” or closed. A DC/DC converter 112 converts V 1 from 12V˜20V to V 2 (such as 5V). V 2 can be used for one or more USB ports 114 through a switch S 2 110 . S 2 110 can be controlled by a controller to protect USB port at over current, short circuit and other abnormal conditions. When the laptop 104 goes into a deep sleep mode or power off conditions (S 1 108 and/or S 2 110 is OFF), the USB ports 114 cannot be used.
SUMMARY OF THE INVENTION
A method of and device for providing one or more voltages to USB ports using an independent electrical channel during a device sleep mode or a power-off mode.
In an aspect, a method of maintaining power supply comprises sensing a sleep mode or a power-off mode of an electronic device and supplying electrical energy through an alternative path to an electric energy output port. In some embodiments, the electric energy output port provides an informational signal. In other embodiments, the electric energy output port comprises a USB port. In some other embodiments, the supplying electrical energy through an alternative path provides an uninterrupted power supply. In some embodiments, the method further comprises sensing an open circuit between a power source and the electric energy output port.
In another aspect, a power supply device comprises an electrical pathway allowing a transmission of electrical energy during a sleep mode of an electrical device. In some embodiments, the electrical pathway comprises a conducting wire. In other embodiments, the conducting wire is within a body of the electrical device. In some other embodiments, the conducting wire further comprises a switch. In some embodiments, the switch is in an open state when the electrical device is not in a sleep mode. In other embodiments, the switch is in a closed state when the electrical device is in a sleep mode.
In another aspect, an electronic device comprises a first electrical circuit, wherein the first electrical circuit is configured to be turned into a sleep mode in a predetermined condition and a second electrical circuit, wherein the second electric circuit is configured to supply power when the first electrical circuit is in the sleep mode. In some other embodiments, the first electrical circuit comprises a first sub-electric circuit and a second sub-electric circuit. In other embodiments, the first sub-electric circuit couples with a battery. In some other embodiments, the second sub-electric circuit couples with a USB port. In some embodiments, the second sub-electric circuit comprises a DC/DC converter. In other embodiments, the second sub-electric circuit comprises a switch. In some other embodiments, the second sub-electric circuit is configured to have a voltage less than 7V. In some embodiments, the second sub-electric circuit is configured to have a voltage close to or equal to 5V. In other embodiments, the electronic device comprises a laptop, a server, a cell phone, or a combination thereof. In some other embodiments, the predetermined condition comprises a non-use for a predetermined duration.
Other features and advantages of the present invention will become apparent after reviewing the detailed description of the embodiments set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described by way of examples, with reference to the accompanying drawings which are meant to be exemplary and not limiting. For all figures mentioned herein, like numbered elements refer to like elements throughout.
FIG. 1 illustrates a typical charging module.
FIG. 2 illustrates a method and device for a charging module in accordance with some embodiments of the present invention.
FIG. 3 illustrates a charging architecture in accordance with some embodiments of the present invention.
FIG. 4 illustrates a method of charging in a device sleeping mode in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention is described in conjunction with the embodiments below, it is understood that they are not intended to limit the invention to these embodiments and examples. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which can be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to more fully illustrate the present invention. However, it is apparent to one of ordinary skill in the prior art having the benefit of this disclosure that the present invention can be practiced without these specific details. In other instances, well-known methods and procedures, components and processes have not been described in detail so as not to unnecessarily obscure aspects of the present invention. It is, of course, appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business related constraints, and that these specific goals vary from one implementation to another and from one developer to another. Moreover, it is appreciated that such a development effort can be complex and time-consuming, but is nevertheless a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
FIG. 2 illustrates a method and device for a charging module 200 in accordance with some embodiments of the present invention. The charging module 200 can include an adaptor 202 coupled with a laptop 204 . The adaptor 202 can output a voltage V 3 in a battery 206 charging mode. In the charging mode, the switch S 3 208 is on “ON.” In one example, a DC/DC converter 212 converts V 3 from a voltage in the range of 12V˜20V to V 4 (such as 5V). V 4 can be used for one or more USB ports 214 through a switch S 4 210 . S 4 210 can be controlled by a controller to protect USB ports at over current, short circuit and other abnormal conditions. When the laptop 204 goes into a deep sleep mode or power off conditions (S 3 208 and/or S 4 210 is/are OFF), the switch S 5 218 of electric loop/circuit 216 in “ON.” The adaptor 202 can provide a V 4 voltage (such as 5V) for powering/charging the one or more devices electrically coupled with the USB ports 214 .
FIG. 3 illustrates a charging architecture 300 in accordance with some embodiments of the present invention. A power source 302 can couple with an electronic device 304 . The electronic device 304 , such as a laptop or a cell phone, comprises a component 306 . The component 306 comprises a sleep mode for saving energy uses. The electrical coupling between the power source 302 and the component 306 can be controlled/regulated via the switch 310 . Independent circuits 316 and 318 can be included as independent charging routes. The circuits 316 and 318 can be controlled by the switches 312 and 314 respectively, such that the power ports 308 A and 308 B can electrically coupled with the power source 302 with switches/controls 312 and 314 .
FIG. 4 illustrates a method 400 of charging in a device sleeping mode in accordance with some embodiments of the present invention. The method 400 can start at Step 402 . At Step 404 , a sleep mode or a power-off mode of a device is determined. The device can be a laptop, a cell phone, or any other electronic devices with a sleep mode mechanism. At Step 406 , electric energy is provided via an alternative route if the device in a sleep mode. At Step 408 , electric energy is supplied to a power outlet, such as a USB, via the alternative route. The method 400 can stop at Step 410 .
The charging mechanism can be utilized for uninterruptedly providing an electric energy to a power port, such as USB ports, while the electric device is in a sleep mode.
In operation, when a sleep mode or a power-off mode is detected, a switch is turned on (close the loop) allowing the alternative electric pathway/circuit for continuously providing electric energy to the one or more USB ports.
The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It is readily apparent to one skilled in the art that other various modifications can be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention as defined by the claims. | A method of and device for providing voltages to USB ports using an independent electrical channel during a device sleep mode or a power-off mode. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Swiss Application no. 00354/06, filed Mar. 3, 2006, which is incorporated herein by reference as if fully set forth.
BACKGROUND
The invention relates to a drive arrangement for the drive elements for threading the upper thread into the eye of the needle of a sewing machine.
Drive arrangements for threading devices of this type are known in many embodiments. They serve to relieve the operator of the sewing machine from the tedious threading of the upper thread into the eye of the needle. Simple threading aids are operated manually, i.e. the upper thread is inserted into a suitable tool and this facilitates the treading process. In automatic threading devices first the thread must be placed in front of the device before the latter then performs the threading process via separate drives in the sewing machine.
The most frequently used automatic threading devices pivot the threader around a horizontal axis downwards from a resting position in the upper arm towards the needle. Further, motorized threading devices are also known in which, similar to the manually operated ones, the threading device is guided vertically downwards along an actuator rod parallel to the needle rod and is pivoted out of this position around said actuator rod. These known threading devices require a suitable electric drive for the lowering process, e.g., a stepper motor, which guides the threading device via a toothed rod downwards and, after the threading, back upwards. Here, the pivoting motion inevitably occurs in a curved path, along which the device at the end of the lowering motion is additionally rotated around the actuator rod.
Both the threading devices with motion around the horizontal axis in the upper arm of the sewing machine as well as those that are vertically displaced by an electric motor need comparatively much space. This leads to a voluminous upper arm housing, which limits the direct visual contact of the operator to the sewing area.
SUMMARY
One object of the present invention comprises providing a drive arrangement for the drive elements for a threader, which requires little space and which, in the resting position, also can essentially be retracted entirely into the upper arm and thus prevents any hindrance to handling during the sewing operation.
This object is attained by a drive arrangement for the drive elements for a threader having the features of the present invention, in which the threader is embodied such that it can be connected to the needle rod actuator that is decoupled from the needle rod. Advantageous embodiments of the device are described below.
By omitting a separate, individual drive, the invention achieves maintaining a small space that is necessary for the processing motions of the threading device, so that there is sufficient room inside a narrow housing. Further, supervision devices are omitted, which control and/or synchronize the respective position of the needle rod and thus the eye of the needle and the threading device. All motions necessary for threading occur automatically synchronized. By omitting one or more additional drive motors for the threading device and alternatively also for the controllable threading motor, the necessary controls and/or the already mentioned synchronization of the individual drives connected thereto is also omitted.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in the following using an illustrated exemplary embodiment. Shown are:
FIG. 1 is a schematic perspective representation of a sewing machine with a lowered threader,
FIGS. 2 a - d are views showing four separate positions of the threader, and
FIGS. 3 a - d are schematic representation of the operating processes of the drive of the threading device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in a schematic representation a household sewing machine 1 with a base plate 3 , a free arm 5 , as well as an upper arm 7 . The free arm as well as the upper arm are connected to each other by the machine housing 9 A threading device 11 is arranged in the front end of the upper arm 7 , which can be deployed from the bottom 13 of the upper arm 7 . In FIG. 1 the threading device 11 is entirely deployed, i.e. lowered. On the upper side of the upper arm 7 schematically a spool holder for the upper thread is shown having an upper thread spool 15 . Further, reference character 17 indicates a needle, having an eye of the needle 19 at its lower end. The needle 17 is connected to the bottom end of a needle rod 21 . A presser foot rod 23 is shown behind the needle rod 21 , with the presser foot 25 being mounted to its lower end.
The elements, briefly described above, are illustrated schematically in more detail in FIGS. 2 a through 2 d , separated from the sewing machine. In FIG. 2 a , the presser foot rod 23 with the presser foot 25 is lifted off the stitching plate 27 on the lower arm 5 by a distance α. The raising of the presser foot 25 occurs in a manner known per se by a lifter lever (or can be motorized), which is not shown therefore to improve visibility. A toothed rod 29 with an actuator 31 is mounted and guided longitudinally parallel to the presser foot rod 23 . A spring 37 is clamped between the lower end 33 of the toothed rod and a bracket 35 mounted to the presser foot rod 23 in a fixed manner. The spring is only slightly stressed when the presser foot 25 is raised. The toothed rod 29 is engaged with a sprocket 39 , which can be driven by an electric motor, e.g., a stepper motor 41 . The reference characters 42 a and 42 b indicate longitudinal guides for the presser foot rod 23 .
In FIG. 2 b the presser foot rod 23 with the presser foot 25 is lowered to the stitching plate 27 via the lifting lever (not shown) or in a motorized manner. Simultaneously the toothed rod 29 has been lowered by the stepper motor 41 and thus the spring 37 has been stressed further. The tensile force of the spring 37 serves to press the presser foot rod 23 with the presser foot 25 toward the stitching plate 27 using the bracket 35 . Thus the pressure of the presser foot 25 to the stitching plate and/or the sewing material (not shown) positioned between the presser foot 25 and the stitching plate 27 can be adjusted by the stepper motor 41 .
The two functions shown in FIGS. 2 a and 2 b are known from prior art and are used in higher priced sewing machines.
In FIG. 2 b it is further discernible that the actuator 31 , which is not included in conventional sewing machines, is positioned at a short distance above the two-armed lever 43 . The two-armed lever 43 is linked to a threader 45 in a mobile fashion. The first leg 43 a of the lever 43 extends below the actuator 31 at a distance; the second leg 43 b of the lever 43 carries a hook 43 c on a free end thereof. The hook is located outside the vertical displacement area of the needle rod actuator 47 in the position of the toothed rod 29 shown in FIG. 2 b . The actuator is connected to the driving device, needle drive 49 for short. The needle drive 49 with the needle rod actuator 47 is known from prior art and comprises, as shown in FIGS. 2 c and 2 d , a crank drive 51 . The actuator 47 is decoupled from the needle rod 21 in the positions shown in FIGS. 2 b through 2 d . When now the toothed rod 29 is further lowered by the stepper motor 41 out of the position shown in FIG. 2 b into the position shown in FIG. 2 c the actuator 31 pivots the leg 43 a of the lever 43 clock-wise such that the hook-shaped end 43 c reaches a position below the needle rod actuator 47 ( FIG. 2 c ). Preferably, a suitable bolt 53 is arranged at the needle rod actuator 47 . Now, the threader 45 can be lowered ( FIG. 2 d ) by the needle rod actuator 47 via the needle drive 49 .
During the lowering of the threader 45 , a threading hook 55 is inevitably pivoted around the axis A of the threader 45 in a curve not shown and the threading process can be performed. The threading process is not described in greater detail, because it can occur in differently operating devices regardless of the processing steps described in FIGS. 2 a through 2 d.
After the threading process the needle drive 49 guides the needle rod actuator 47 upwards, which simultaneously causes the threader 45 to be returned into the resting position by the tensile force of a second spring 57 stressed during the lowering of the threader 45 .
Similar to the exemplary embodiment in FIGS. 1 and 2 a - 2 d , for the motion drive of the threader 11 with the already existing drives for the needle rod 21 and the presser foot pressure the transfer of the upper thread can also lead to a deflection, which increases the wrapping angle of the thread brake 61 , and thus leads to the insertion of the thread regulator (not shown) having an existing drive, namely the drive motor 59 for the thread brake 61 . In FIGS. 3 a through 3 d , in four steps, it is shown schematically how, on the one side, the structure of the braking force occurs in the thread brake 61 with the drive motor 59 of the thread brake 61 and how a thread deflection lever 73 can be operated by the same motor.
In the illustrations in FIGS. 3 a - 3 d , the thread brake 61 is shown, which comprises two discs that can be elastically pressed against each other (not shown in detail). The two discs are located axially behind the thread brake 61 , shown schematically as a circular plate. An actuator disc 63 , its periphery being embodied as a sprocket, which is engaged by a driving sprocket 65 of the drive motor 59 , is arranged between the drive motor 59 and the thread brake 61 . At the face of the actuator disc 63 , a toothed segment 67 is arranged pivotal around the rotary axis A of the actuator disc 63 , which includes a protrusion 69 on one side. The protrusion 69 contacts the cam 71 in the resting position ( FIG. 3 c ). A thread displacement lever 73 is pivotally arranged on a pivot axis B located outside the periphery of the actuator disc 63 . In the area of the deflection of the thread deflection lever 73 , the lever is provided with a toothed segment 75 , which engages the teeth of the toothed segment 67 on the actuator disc 63 . An actuator hook 77 is formed at the free end of the thread displacement lever 73 .
FIG. 3 c shows, as already mentioned, the resting position of the actuator disc 63 , in which the first toothed element 67 contacts the cam 71 and in which the thread brake 61 and the two discs forming the thread brake 61 are at a distance (from each other) so that the upper thread can be inserted thereto. In a known fashion, after the threading of the thread by the drive motor 59 , the thread brake 61 and/or a spindle are driven, thus the two discs of the thread brake 61 approach one another. Here, the cam 71 moves on the actuator disc 63 counter-clock wise by approx. 180° ( FIG. 3 b ). When the thread tension must be increased even more, the drive motor 59 further rotates the actuator disc 63 in the counter-clockwise direction until the cam 71 approaches the protrusion 69 on the first toothed segment 67 from the other side (cf. FIG. 3 a ).
At the beginning of the threading process for the upper thread the thread brake 61 is in the resting position according to FIG. 3 c . In order to achieve an optimum deflection of the upper thread into the thread brake 61 and/or to insert the thread into the thread regulator, the upper thread 79 , initially extending in a straight manner, must be deflected towards the thread brake 61 . This occurs via the thread deflection lever 73 , with its actuator hook 77 grasping the upper thread and transferring it from the initial position X into the deflection position Y. In order to transfer the thread deflection lever 73 from position X into position Y the rotational direction of the drive motor 59 is reversed so that the actuator disc 63 rotates in the clockwise direction. Here, the cam 71 also rotates the first toothed segment 67 in the clockwise direction and thereby pivots the thread deflection lever 73 engaging the toothed segment 67 into the position Y ( FIG. 3 d ).
As soon as the thread deflection lever 73 reaches position Y, the upper thread leaps over a deflection protrusion, not shown, and is guided there such that the thread deflection lever 73 is returned into the resting position by rotating the drive motor 59 in the opposite rotational direction and, when the motor 59 continues to rotate in the same rotational direction the thread brake 61 , according to FIGS. 3 b and/or 3 a , can be stressed. The drive motor 59 of the thread brake 61 therefore performs two entirely different tasks: at the beginning of the threading process the thread deflection lever 73 pivots out of the resting and catching position into the transfer position Y and subsequently it serves to regulate the thread brake 61 .
List of Reference Characters
1 sewing machine
3 base plate
5 free arm
7 upper arm
9 machine housing
11 threading device
13 bottom of
15 upper thread spool
17 needle
19 eye of the needle
21 needle rod
23 presser foot rod
25 presser foot
27 stitching plate
29 toothed rod
31 actuator
33 bottom end of 29
35 bracket
37 spring
39 sprocket
41 stepper motor
42 longitudinal guidance
43 two-armed lever
45 threader
47 needle rod actuator
49 needle drive
51 crank drive
53 bolt
55 threading hook
57 spring
59 drive motor for thread brake
61 thread brake
63 actuator disc
65 sprocket for downward drive
67 toothed segment
69 protrusion
71 cam
73 thread deflection lever
75 toothed segment
77 actuator hook
79 upper thread | A drive arrangement for the drive elements for the threading of the upper thread into the eye of a sewing machine needle is provided. Instead of individual drives for lowering the threading device and rotating it as well as threading the thread regulator to deflect the upper thread around the thread brake, drives not used at that time for the needle rod, the presser foot pressure, and the thread brake are utilized. In this way, two to three additional electric drives can be omitted and thus the controlling expense can be reduced. | 3 |
Background of the Invention
1. Field of the Invention
This invention relates to injecting one or more phases of steam into one or more formations from a single string of tubing by utilizing an impingement means in a side pocket mandrel or other downhole tools and including, if desired, an agitation device to control the quality and flow of steam. The invention may also include a centralizer to guide a tool string and disperse the steam.
2. Description of Related Art
In the past, various configurations of devices were used to inject steam and other fluids and gases into one or more zones of a formation to enhance hydrocarbon recovery, such as oil, from the earth. Depending on the medium injected and the properties of the formation, some of these devices were more successful than others.
Early injection techniques usually involved drilling a hole for each formation zone in a selected area. This horizontal expansion method of enhanced recovery is extremely expensive and time-consuming. A more economical method would entail servicing the various zones in a formation by way of multiple injection points in a single drilled hole.
A related patent, U.S. Pat. No. 4,248,302, answering the need for multiple zone injection from a single drilled hole was granted to Ronald K. Churchman and was assigned to Otis Engineering Corporation. Although particularly addressing pumpdown (through the flow line) completions, the patent does show using one or more side pocket mandrels to inject fluids and steam into one or more wells and/or formation zones. This method and apparatus was an advancement in the field of steam injection.
As interest in injection increased, several zones in a formation were serviced from a single drilled hole by utilizing concentric tubing. Such a configuration is shown in U. S. Pat. No. 3,319,717 by D. V. Chenoweth, U.S. Pat. Nos. 4,081,032, 4,099,563 and 4,399,865 by S. O. Hutchinson and G. W. Anderson and U.S. Pat. No. 4,081,028 by E. E. Rogers. All these devices allow steam or hot fluids to flow through the inner tubing to the next distributing apparatus while providing a passage for the steam or hot fluids to flow into the casing-tubing annulus and into a selected zone. While an improvement on multiwells, these devices did not allow the operator to deliver a calculated percentage of steam and hot fluid to a particular zone nor did they control the quality of the steam at several points in the well bore. Also the operator could not run maintenance tools down the tubing string to rework the downhole devices. Testing of this type of device showed that heat transfer between the concentric tubes created a heat loss from one tube to the other and created undesirable tubing movement. Chenoweth's U.S. Pat. No. 3,319,717 device was retrievable but had to be removed from the tubing string before any survey or maintenance tools could be run below the device. Oilfield operators wanted a system more controllable and more easily maintained.
U.S. Pat. No. 3,455,382 by D. V. Chenoweth solved part of the maintenance problem by injecting into different zones with a pressure regulator placed in a side pocket mandrel. Tools to service the downhole devices could then be passed by the pressure regulators without removing them. The function of the pressure regulators was to keep the single phase injection fluids going through the exit port in the side pocket mandrel and into the tubing-casing annulus at a constant rate regardless of tubing pressure upstream or downstream of the pressure regulator. However, Chenoweth's device did not address the problem of providing a desired percentage of vapor and hot fluids to one or more separate formation zones. This device did not, because of its throttle-like action, allow the user to calculate a critical flow relationship utilizing known input pressures of injected fluid or steam. The present invention does allow the user to calculate a critical flow relationship and also has the advantage of having no moving parts.
SUMMARY OF THE INVENTION
The present invention includes an impingement means and other means within the flow passageway of a side pocket mandrel or other downhole tools to mix and direct the flow of steam and inject the steam into the formation. Steam is defined throughout this application to mean vapor and hot fluid or any combination thereof unless addressed separately as hot fluid or vapor. The steam is used to aid in the recovery of viscous petroleums, usually on the order of one to 1,000,000 centipoise at reservoir temperatures, by heating the petroleum with the steam.
The side pocket mandrel or other downhole tool is connected to a source of pressurized steam. The steam is pumped under pressure to the side pocket mandrel or other downhole tools through flow conductors. The steam as it leaves the source is mostly of a vaporous nature. As it travels through the flow conductors, it has a tendency to separate into a combination of vapor and hot fluid. A portion of this hot fluid including some vapor clings to the wall of the flow conductor in a more or less laminar manner while the remaining vapor continues down the center of the flow conductors.
In order to recombine the vapor and the hot fluid into a desired percentage of each, the impingement means mixes the two phases. This is accomplished in a chamber formed between the impingement means and the wall of the longitudinal flow passageway of the side pocket mandrel or other downhole tools. Primarily, hot fluid enters the grooves of the impingement means and is directed through the chamber formed by the impingement means and the wall of the longitudinal flow passageway of the side pocket mandrel body or other downhole tools by way of the radial directing means which in the preferred embodiment is a spirally-cut set of lands and grooves. The vapor phase of the steam flows into and is deflected by the fingers of the impingement means into the longitudinal flow passageway of the impingement means. These fingers also serve to guide tools through the impingement means. One or more holes through the wall in the impingement means allow the vapor to enter grooves formed on the outside diameter of the impingement means and the chamber formed between the outside diameter of the impingement means and the wall of the longitudinal flow passageway of the side pocket mandrel body or other downhole tools.
After mixing, a percentage of the steam enters a valve means which regulates the flow of steam into the tubing-casing annulus and into the formation zone through the perforations or flows out through drain holes in the impingement means to continue down toward other downhole equipment. The valve means could be, among other devices, a choke means. In the preferred embodiment, an offset choke means referred to as a valve means is used. Vapor and hot fluid that did not enter the chamber, as described above, flow through the longitudinal flow passageway and on to other downhole equipment.
The present device injects a preferred percentage of hot fluid and vapor into the formation zones at preselected intervals thus warming the viscous petroleum and enhancing its flow characteristics.
The impingement means can be placed in a downhole tool, other than a side pocket mandrel, that has a longitudinal flow passageway in which to place it. Flow of hot water and vapor could then be diverted percentage-wise by the impingement means into the ports provided in the downhole tool or on through the longitudinal flow passageway to other downhole equipment.
It is therefore one object of the present invention to provide an apparatus for enhanced oil recovery by steam injection.
It is a further object of this invention to provide an impingement means and, if desired, an agitation means in a side pocket mandrel or other downhole tools to inject a controlled percentage of hot fluid and vapor into a formation zone.
It is another object of this invention to agitate and recombine multiphased steam flow in a side pocket mandrel or other downhole tools using an impingement means and, in selected embodiments, an agitation means and/or a centralizer means.
It is yet another object of this invention to provide a centralizer means or an agitation means in a side pocket mandrel or other downhole tools that will also guide tools through the impingement means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B taken together constitute a longitudinal view, in section, showing the side pocket mandrel with a centralizer means, an impingement means and a valve means.
FIG. 2 is a longitudinal view, in section, showing an impingement means constructed in accordance with the present invention.
FIG. 3 is a top view of FIG. 2.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 1A showing a centralizer means located in the side pocket mandrel.
FIG. 5 is a cross-sectional view taken along line 5--5 of Figure 1B showing the top view of an impingement means and a valve means seated in its pocket in the side pocket mandrel. The chamber formed between the outside diameter of an impingement means and the wall of the longitudinal flow passageway of the side pocket mandrel is also shown.
FIG. 6 is a cross-sectional view taken along line 6--6 of Figure 1B showing the relationship of a port means, shown as holes, in the wall of an impringement means and the ports in the valve means in the valve pocket.
FIG. 7 is a longitudinal view, partly in section and partly in elevation, showing an agitation means as placed in an alternate embodiment of the invention.
FIG. 8 is a longitudinal view, partly in section and partly in elevation, showing a side pocket mandrel of a different design than that shown in Figures 1A and 1B.
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 8 showing an oval or eliptical shaped mandrel configuration and the chamber formed between the outside diameter of an impingement means and the wall of the longitudinal flow passageway of this design side pocket mandrel.
FIG. 10 is a cross-sectional view taken along line 10--10 of FIG. 8 showing a round shaped mandrel configuration and the chamber formed between the outside diameter of an impingement means and the wall of the longitudinal flow passageway of this design side pocket mandrel.
FIG. 11 is a longitudinal view, partly in section and partly in elevation, showing an alternative embodiment of the invention with an agitation means placed in the belly of the side pocket mandrel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to Figures 1A and 1B, the side pocket mandrel 20 may have various round or nonround cross-sectional shapes. Although many cross-sectional configurations are available to one skilled in the art of side pocket mandrel design, the shapes most used are round, oval and elliptical. Two of these shapes are shown in FIGS. 9 and 10 which are examples of possible cross-sections of the side pocket mandrel shown in FIG. 8.
An upper crossover sub (not shown) with threads compatible with upper side pocket mandrel body thread 31 may be used to connect the crossover sub to the side pocket mandrel 40 if centralizer means 21 is not used. The crossover sub would also contain a thread similar to upper centralizer means thread 30 that would connect side pocket mandrel 20, by means of the upper crossover sub, to a source of pressurized steam (not shown).
As shown in Figures lA and lB, the centralizer means 21 is connected at one end to a source of pressurized steam by upper centralizer means thread 30 and is connected to one end of the side pocket mandrel body 40 by lower centralizer means thread 32 which is mated to upper side pocket mandrel body thread 31. This is another example of possible means to connect side pocket means 20 to a source of pressurized steam. The impingement means 22 is connected to the other end of the side pocket mandrel body 40 by the upper impingement means thread 34 mated with lower side pocket mandrel body thread 33. The lower impingement means thread 35 and thereby side pocket mandrel 20 can be connected to other downhole well equipment (not shown). One skilled in the art would realize that other connecting methods other than threads could be used.
Pressurized steam enters the centralizer means 21. Centralizer means 21 contains a second mandrel means 60 having a third longitudinal flow passageway 63 therethrough. The third longitudinal flow passageway 62, through which the steam flows, has its inner diameter reduced to form the venturi means 61 as shown in Figure 1A. The venturi means 61 serves at least two functions. It provides for guidance of tools through the side pocket mandrel 20 and causes a pressure change and dispersion of the steam that passes through the venturi means 61.
The steam then enters side pocket mandrel body 40 by way of the first longitudinal flow passageway 41. As the steam flows from its source, it tends to form laminae (not shown) of various combinations of vapor and hot fluid. The recombination or remixing of the various phases and laminae of the steam is further accomplished by impingement means 22.
The impingement means 22 is shown in place in side pocket mandrel 20 in Figure 1B, in an enlarged view in FIG. 2 and is shown in a top view in FIG. 3. The impingement means 22 includes a first mandrel means 50 having a second longitudinal flow passageway 51 therethrough and a helical directing means 52 which, in the preferred embodiment, is a set of spirally cut lands 91 and grooves 92 formed on the outside diameter 58 of the first mandrel means 50. The helical directing means 52 could be a set of threads of which several different configurations are available. Also included in the impingement means 22 is longitudinal directing means 53 which includes alternating fingers 54 and slots 55 on one end of the first mandrel means 50. In FIG. 2, a second port means 56, shown as holes through the wall of the first mandrel means 50, allows communication of steam between the second longitudinal flow passageway 51 and the first longitudinal flow passageway 41. Referring to FIGS. 5 and 6, the impingement means 22 also includes a third port means 57 for draining steam from the chamber 42 formed between the wall of the first longitudinal flow passageway 41 and the outer diameter 58 of the first mandrel means 50. The steam from chamber 42 flows back into second longitudinal flow passageway 51 of first mandrel means 50 through third port means 57 and out of side pocket mandrel 20.
As the laminae of hot fluid and vapor form on the surfaces of the equipment above impingement means 22, vapor also flows as a more or less separate phase down through the center of the longitudinal flow passageways. The laminae of hot fluid and vapor strike the fingers 54 and the slots 55 of the longitudinal directing means 53. The laminae of hot fluid and vapor are diverted or directed through slots 55 into chamber 42 and into the spirally cut lands 90 and grooves 91 of the helical directing means 52. As the vapor phase of the steam enters the second longitudinal flow passageway 51, part of the vapor enters chamber 42 and helical directing means 52 by way of the second port means 56. Part of the vapor is deflected into the second longitudinal flow passageway 51 by fingers 54 and continues to flow out of the side pocket mandrel 20 through the second longitudinal flow passageway 51 of impingement means 22.
As the laminae of hot fluid and vapor are directed helically around impingement means 22 and through chamber 42 by the helical directing means 52, the laminae meet and are mixed with the vapor phase of the steam entering the helical directing means 52 and the chamber 42 through second port means 56.
The shape, number and configuration of the fingers 54 and slots 55 of the longitudinal directing means 53; the size of the chamber 42; the number, location and size of second port means 56; the size and configuration of the lands 91 and grooves 92 of helical directing means 52; the size of first mandrel means 50; and the size, number and location of third port means 57 affect the quality or percentage of hot fluid to vapor that is mixed in chamber 42 and enters the fourth port means 45 once the hot fluid and vapor reaches the impingement means 22.
Communication from chamber 42 to valve pocket 44 is accomplished by the steam passing through fourth port means 45. The amount of steam entering first port means 46 is controlled by valve means 24 located in valve pocket 44.
Valve means 24 is comprised mainly of latch means 80, control means 81, seal means 82 and flow direction means 83. Latch means 80 allows for placement, removal and replacement of the valve means 24 by downhole wireline tools (not shown) familiar to those skilled in the art of placing and retrieving equipment with standard latch means. Valve means 24 is similar in construction to the chemical injection valve shown on page 6238 of the Otis Engineering Corporation section of the 1984--85 Edition of The World Oil Composite Catalog. The seal means 82 and the flow direction means 83 prevent the steam from entering the valve pocket 44 by any other path other than fourth port means 45 or leaving by any other path than first port means 46 by way of flow direction means 83. Flow direction means 83 can be a one-way valve to allow flow of steam in only one direction. Valve means 24 can be installed without flow direction means 83. First port means 46 could be fitted with a means to direct the flow of steam or with a venturi means to expand and dispense the steam. The steam is now able to enter the formation after passing through the perforations (not shown).
Other factors influencing the percentage or quality of the steam arriving at the first port means 46 include the quantity and quality (percentage of hot fluid to vapor) available at the side pocket mandrel 20 and the influences equipment above impingement means 22 has on the steam. In alternative embodiments of the invention, a centralizer means 21 and/or an agitation means 23 are utilized in the side pocket mandrel 20.
The centralizer means 21, previously discussed, may be placed in the side pocket mandrel body 40 in lieu of a crossover sub (not shown). The agitation means 23 can also be placed in the same location in the side pocket mandrel body 40 just as was the centralizer means 21. One of the alternative embodiments showing the agitation means 23 in place is shown in FIG. 7. Another alternative embodiment showing the agitation means 123 is shown in FIG. 11.
Referring to FIG. 7, agitation means 23 is comprised mainly of third mandrel means 70, fourth longitudinal flow passageway 71 and one or more sets of interior lands 72 and grooves 73. The sets of interior lands 72 and grooves 73 may be any design of land or groove familiar to those skilled in the art and, as shown in FIG. 7, may be helically-cut and threadlike in construction. They may also alternate in the direction of their spiral as shown in FIG. 7 or may be cut in the inside diameter of third mandrel means 70 in only one direction. Third mandrel means 70 is connected to side pocket mandrel body 40 by lower agitation means thread 36 which mates with upper side pocket mandrel body thread 31. Upper agitation means thread 37 is the means for connecting the other end of the third mandrel means 70 to the source of pressurized steam.
The agitation means 23 amalgamates the hot fluid and vapor in preparation for entering the impingement means 22 where the steam is further blended. As steam enters the third longitudinal flow passageway 62, the laminae of hot fluid and vapor are agitated by the lands 72 and the grooves 73 by turbulence and also by the alternating direction of flow caused by the reversed direction of the spiral formed by the lands 72 and grooves 73. The amalgamated steam then flows through the first longitudinal flow passageway 41 and on to the impingement means 22 as described above. The third mandrel means 70 may also be designed to provide guidance of tools through the side pocket mandrel 20 and especially through impingement means 22.
An alternative embodiment of side pocket mandrel 20 is side pocket mandrel 120 shown in FIG. 11. The flow and blending of steam to be provided to the formation is accomplished in much the same manner as the other embodiment except that the agitation means 121 is located lower in first longitudinal flow passageway 141 than the agitation means 23 was in first longitudinal flow passageway 41 shown in FIG. 7. This embodiment allows centralizer means 121, which is identical to centralizer means 21, to be utilized with agitation means 123. Centralizer means 123 is attached to side pocket mandrel body 140 in the same manner as described for centralizer means 23 in side pocket mandrel body 40. This combination of centralizer means 121 and agitation means 123 allows the user to enhance the mixing and blending of the steam if considered necessary to provide the selected or calculated quality or percentage of hot fluid and vapor to the formation. Impingement means 122 is identical to impingement means 22 and is attached to side pocket mandrel body 140 in the same manner as described for agitation means 22 in side pocket mandrel body 40.
The foregoing descriptions and drawings of the invention are explanatory and illustrative only, and various changes in shapes, sizes and arrangements of parts as well as certain details of the illustrated construction may be made within the scope of the appended claims without departing from the true spirit of the invention. | An impingement device in a side pocket mandrel or other downhole tools for injecting a predetermined quality of steam in one or more zones of a formation. The impingement device directs and mixes the laminae of hot fluid and vapor and a valve in a valve pocket controls the flow of steam to the zone from the side pocket mandrel or other downhole tools. Along with the impingement device, a centralizer to guide tools through the impingement device and to cause a pressure change and dispersion of the steam; and an agitation device to amalgamate the steam may be used if further blending is required. | 4 |
FIELD OF THE INVENTION
The invention relates to a fire extinguishing system with a method to prevent or extinguish fires, and more particularly, a fire suppression system having frangible extinguishant holders and automatic receptacles.
BACKGROUND
Several systems have attempted to deal with the issue of electrical fires and lithium-ion battery fires in particular. U.S. Pub. Appl. No. 2009/0014188 describes a device for containing ignited electrical equipment. The device includes a main body having an opening and volume sufficient to contain the electrical device and a flap to cover the opening to the main body when the electrical device is contained within the main body. By covering the opening with the flap, the lithium ion battery fire is contained within the device and not allowed to spread. However such a system does not deal with a thermal runaway reaction or a resulting fire, the system merely isolates these dangerous conditions from other cells in the battery.
U.S. Pat. No. 8,273,474 is a battery thermal management system where electrochemical cell battery systems and associated methods of operation are provided based on the incorporation of a thermal management matrix including a supply of phase change material disposed at least in part to a heat conductive lattice member to effectively dissipate heat produced or generated by or in the battery system. However such a system is only meant to cool a battery cell and if fire still occurs there is no method to suppress it.
U.S. Pub. Appl. No. 2010/0078182 is a device for generating and storing electrical or mechanical energy, and method for fire avoidance where an encapsulation in which at least one element of the device serving to generate or store electrical or mechanical energy is positioned, and having a container for flame-retardant substance. The substance store in the container releases a flame-retardant component if need be. However this system does not isolate each cell from another to prevent damage to other cells. Furthermore, this system has no method for activating in the presence of open flame.
SUMMARY
A fire suppression system furnishes a device to suppress fires generated by lithium-ion batteries. The device can include one or more battery cells, where each cell can be encased in a protective enclosure. Each enclosure can have an opening on one end. The enclosures define an empty volume or free space after a cell is inserted. A fluid delivery system can carry a fire-retarding or heat-dissipating fluid agent for delivery of the agent to the empty volume or free space of any given enclosure.
The device can include one or more battery cells, where each battery cell can be encased in a protective enclosure. Each enclosure can have an opening on one end, and the opening can be fitted with a cap to close the enclosure. Each cap can be disengaged from the opening of the enclosure. Each cap can include a pressure relief system in order to decrease pressure inside the corresponding enclosure. One or more temperature and flame sensitive tubes carrying a fire-retarding or heat-dissipating fluid agent can pass through each enclosure. When the temperature increases or a fire starts inside a given enclosure, the part of the tube inside the enclosure ruptures and the fluid agent can be delivered to the empty volume or free space of the given enclosure.
The device can include multiple battery cells, where each cell can be encased in a separate independent protective enclosure. Each enclosure can have an opening at one end with a cap fitted to engage and to sealingly close the enclosure. Each cap can be disengaged from a corresponding enclosure for battery cell maintenance. One or more temperature sensitive tubes carrying a fire-retarding or heat-dissipating fluid agent can pass through each enclosure in a serpentine or straight line fashion. When the temperature increases inside one or more enclosures due to an enclosed battery cell exhibiting a thermal runaway, a portion of the tube inside the affected enclosure can rupture and the fluid agent can be delivered to the empty volume or free space defined between the battery cell and a wall of the corresponding enclosure.
Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 is a cross-sectional view of one enclosure;
FIG. 2 is a top view of one enclosure;
FIG. 3 is a bottom view of one enclosure;
FIG. 4 is a simplified isometric view of a plurality of enclosures mounted vertically; and
FIG. 5 is a simplified isometric view of a plurality of enclosures mounted horizontally.
DETAILED DESCRIPTION
Referring now to FIG. 1 , a cross-sectional view shows an elongate enclosure 10 . The elongate enclosure 10 can have an opening 12 at one end defining an interior volume 14 . The elongate enclosure 10 can house a cell 28 of a lithium-ion battery. The elongate enclosure 10 can leave the positive and negative terminals 42 of the cell 28 exposed. The exposed positive and negative terminals 42 can be connected to a battery grid board 40 with one or more connectors 44 . The positive and negative terminals 42 can plug into the corresponding connectors 44 as the battery cell slides within the corresponding elongate enclosure 10 into place. A container 36 can enclose a supply of a fluid agent 18 . The container 36 can be in fluidic contact with the interior volume 14 of the elongate enclosure 10 via a fluid delivery system 16 .
The elongate enclosure 10 can be constructed in such a way so as to be airtight. In the event of a cell fire, the elongate enclosure 10 can prevent the entry of oxygen from the air and can prevent the fire and elevated temperatures from spreading. Each cell 28 can be housed separately in one elongate enclosure 10 or housed together. The elongate enclosure 10 can be made out of any thermally insulating material, by way of example and not limitation, such as ground glass, graphite or ceramic. The material chosen depends on the environment in which the invention is being used. For instance, in applications where cost is a consideration, but the weight and total volume occupied by the invention are not, ground glass can be used. If lower weight, lower total volume occupied and ability to withstand increased temperatures are desired, then ceramic or graphite can be used. However, since the elongate enclosure 10 serves to thermally insulate the cell 28 , any thermally insulating material can be used to fabricate the elongate enclosure 10 .
The fluid delivery system 16 can be fastened to the container 36 and can run through the interior volume 14 of the elongate enclosure 10 . Static or dynamic pressure can be used to move the fluid agent 18 from the container 36 into the fluid delivery system 16 . The fluid delivery system 16 can allow the delivery of the fluid agent 18 from the container 36 to the interior volume 14 of the elongate enclosure 10 in the event of a thermal runaway or cell fire. The fluid delivery system 16 can incorporate a temperature and/or flame sensitive tube 38 . In the event of a thermal runaway or cell fire, the elevated temperatures or open flame can cause the temperature and/or flame sensitive tube 38 to rupture, releasing the fluid agent 18 into the interior volume 14 of the elongate enclosure 10 . The release of the fluid agent 18 allows the fluid agent 18 to come into thermal contact with the cell 28 resulting in cooling of the cell 28 and retarding of any fires existing in the elongate enclosure 10 . This operation results in a passive system that does not require user intervention. However, it should be recognized by those skilled in the art that various levels of user intervention can be implemented, if so desired. The temperature and/or flame sensitive tube 38 can be made out of any material meant to rupture in response to exposure to a certain temperature and/or after exposure to open flame. A suitable material for the temperature and/or flame sensitive tube 38 should be resistant to rupture during the normal operating temperature of the cell 28 . The material can also be chosen so the fluid agent 18 resists chemical reaction with the temperature and/or flame sensitive tube 38 to cause a premature rupture.
The fluid agent 18 can be any agent meant to suppress, retard or prevent fires, or any agent meant to absorb or dissipate heat. By way of example and not limitation, the agent can be a foam or an aqueous based solution. The aqueous based solution can be water plus the inclusion of a water soluble additive meant to increase fire retarding effectiveness or decrease the volume of water needed to effectively fire retard such as FEM-12SC, FireBane 1170, or Cold Fire 302. The agent sold under the commercial name FEM-12SC is manufactured by TLI Group Ltd. located in Carver, Mass. The agent sold under the commercial name FireBane 1170 is manufactured by GSL, Inc. located in Tulsa, Okla. The agent sold under the commercial name Cold Fire 302 is manufactured by Firefreeze Worldwide, Inc. located in Rockaway, N.J.
The elongate enclosure 10 can incorporate a cap 20 on the opening 12 end. The cap 20 can serve to close the opening 12 . The cap 20 can be released from the elongate enclosure 10 for battery cell maintenance. In the event of a malfunctioning cell, by way of example and not limitation, exhibiting thermal runaway, the cap 20 can be disengaged from the elongate enclosure 10 in order to remove and properly handle the malfunctioning cell.
The cap 20 can incorporate a pressure relief system 22 . In the event of a cell fire, a gas will build up inside the elongate enclosure 10 causing an increase in pressure. As pressure inside the elongate enclosure 10 rises, the risk of explosion increases. The pressure relief system 22 can enable release of pressure from the interior volume 14 of the elongate enclosure 10 to a volume outside of the elongate enclosure 10 . The pressure for opening up the contact between the interior volume 14 of the elongate enclosure 10 to a volume outside the elongate enclosure 10 can be selected so the pressure can be relieved before becoming sufficiently high to cause an explosion.
A second seal member 32 can extend between the cap 20 and the wall of the elongate enclosure 10 . The second seal member 32 can be made out of any material which allows the second seal member to form an airtight seal between the cap 20 and the wall of the elongate enclosure 10 .
Referring now to FIG. 2 , a top view illustrates the cap 20 can incorporate a fluid release system 34 . In the event of a cell fire, the fluid delivery system 16 delivers fluid agent to the interior volume 14 of the elongate enclosure 10 . The fluid release system 34 can enable a controlled rate of leakage from the interior volume 14 of the elongate enclosure 10 to the volume outside of the elongate enclosure after the interior volume 14 has been filled with liquid. The controlled rate of leakage can assist in temperature and/or heat dissipation as well as pressure relief. It should be recognized that the controlled rate of leakage determines a time period of delivery of the fluid agent 18 to any battery cell 28 within an elongate enclosure 10 experiencing an abnormal thermal event, and that the time period can be affected by the volume of agent storage, the controlled rate of leakage, and the number of battery cells experiencing abnormal thermal events simultaneously or consecutively.
Referring now to FIG. 3 , a bottom view shows that a first seal member 30 can extend between the cell 28 and the wall of the elongate enclosure 10 adjacent an end opposite from the cap 20 . The first seal member 30 can be made out of any material which allows the first seal member 30 to form an airtight seal between the cell 28 and the wall of the elongate enclosure 10 .
Referring now to FIG. 4 , a simplified isometric view shows a plurality of elongate enclosures 10 mounted with corresponding axes extending vertically and parallel to one another 24 . The fluid delivery system 16 can be fastened to the container 36 and can contain the fluid agent. The fluid agent can run through each of the elongate enclosures 10 in a serpentine and/or straight line fashion, terminating at the last elongate enclosure. The container 36 can provide fluid communication with one or more interior volumes of the elongate enclosures in response to the rupture of the fluid delivery system 16 within one or more elongate enclosures.
Referring now to FIG. 5 , a simplified isometric view shows a plurality of elongate enclosures 10 mounted with corresponding axes extending horizontally and parallel to one another 26 . The fluid delivery system 16 can be fastened to the container 36 and can contain the fluid agent. The fluid agent can run through each of the elongate enclosures 10 in a serpentine and/or straight line fashion, terminating at the last elongate enclosure. The container 36 can provide fluid communication with one or more interior volumes of the elongate enclosures in response to the rupture of the fluid delivery system 16 .
Referring now to FIG. 1 , in operation the fire suppression system moves fire retarding or heat dissipating fluid agent 18 from the container 36 into the temperature and/or flame sensitive tube 38 by gravity or pressure generating equipment such as, by way of example and not limitation, pumps or pressurized gas, such as nitrogen. When a cell 28 undergoes thermal runaway, heat is generated and eventually fire will erupt. In response to either the temperature reaching a certain threshold or open flames reaching the temperature and/or flame sensitive tube 38 , the temperature and/or flame sensitive tube 38 will rupture, causing the release of the fire-retarding or heat-dissipating fluid agent 18 onto the cell 28 . The cell 28 and the fire-retarding or heat-dissipating fluid agent 18 can come into thermal contact resulting in cooling of the cell 28 and suppression of any fires existing in the elongate enclosure 10 . The cap 20 on the elongate enclosure 10 can then be removed in order to properly remove and dispose of the malfunctioning cell.
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 embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. | A device for suppressing fires generated by lithium-ion batteries exhibiting thermal runaway. The device can include a thermally insulating enclosure for housing one or more battery cells. A fluid delivery system having a heat/temperature sensitive tube passes through each enclosure and contains an agent capable of extinguishing fires. When the cell or battery starts to undergo thermal runaway, the increase in temperature or the eruption of open flame causes the fluid delivery system to rupture inside the enclosure. The agent leaks out of the rupture and is transported into the enclosure and onto the malfunctioning cell or battery. Any fire is suppressed and the cell or battery is cooled down by the agent. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a ball joint used, for example, at a connection portion of a vehicle stabilizer.
[0003] 2. Description of the Related Art
[0004] Thus type of ball joint is, as disclosed in Japanese Patent Application Laid-Open (JP-A) No. 8-284948, constructed so that a ball portion at one end portion of a ball stud is slidably fitted together with a ball seat and the ball stud is universally pivotably-supported. Furthermore, in order to fix it to a mounting member, the distal end side of the ball stud, at which a screw portion is formed, is passed through the mounting member, and a nut is screwed into the screw portion and fastened. The mounting member is thereby sandwiched by the seat surface portion formed at the ball stud and the nut, and is fastened.
[0005] When the nut is fastened and the ball stud is fixed to the mounting member, because the ball stud freely rotates with respect to the ball seat, if the rotation torque of the nut exceeds the frictional resistance of the seat surface portion for the mounting member, co-rotation in which the ball stud co-rotates along with the nut occurs, and fastening cannot be carried out. In a conventional art, a hexagonal head wrench is fitted with a hexagonal socket formed at the distal end surface of the ball stud, and due to the ball stud being regulated, fastening of the nut is possible. However, the fastening work is troublesome and this is unsatisfactory arises. Thus, in the above-described publication, it is proposed that a co-rotation preventing plate, whose area is greater than that of the seat surface, is sandwiched between the seat surface and the mounting member, and the co-rotation is prevented by increasing the frictional resistance with respect to the mounting member by the co-rotation preventing plate.
[0006] However, if the co-rotation preventing plate is used, an increase in the number of parts and the troublesomeness of assembly work in accordance therewith are brought about. Furthermore, it is supposed that there are cases in which, in accordance with the state of the degree of surface roughness of the abutting surfaces of the mounting member and the co-rotation preventing plate, the increase in frictional resistance is slight, and co-rotation cannot be reliably prevented.
SUMMARY OF THE INVENTION
[0007] Thus, an object of the present invention is to provide a ball joint which, without leading to an increase in the number of parts and the accompanying troublesomeness of assembly work, can reliably prevent co-rotation of a ball stud.
[0008] The present invention provides a ball joint comprising: a ball stud having a stud portion at a middle thereof, a ball portion and a screw portion at opposite sides of the stud portion, and a seat surface portion facing the screw portion between the respective portions; and a bearing member into which the ball portion is slidably fitted so as to universally pivotably-support the ball stud, so that the stud portion is inserted through a mounting member, and a nut is screwed with the screw portion projected from the mounting member, and the seat surface portion abuts and is fastened to the mounting member by fastening the nut to the mounting member. The seat surface portion abutting the mounting member is subjected to a co-rotation preventing process which prevents the ball stud from co-rotating along with the nut when the nut is fastened.
[0009] In accordance with the ball joint of the present invention, because a co-rotation preventing process is applied to the seat surface portion of the ball stud, the co-rotation preventing process works on the mounting member when the nut is fastened, and the ball stud is prevented from co-rotating along with the nut. Accordingly, without leading to an increase in the number of parts and the accompanying troublesomeness of assembly work, the co-rotation of a ball stud can be reliably prevented.
[0010] A specific example of the co-rotation preventing process relating to the present invention is the forming of projections biting into the mounting member in a fastened state. In this case, when the nut is fastened and the seat surface portion is fastened to the mounting member, the projections bite into the mounting member, and the co-rotation of the ball stud is prevented. The projections are preferably a sharp shape easily biting into the mounting member, and when painting is carried out on the mounting member, the co-rotation can be sufficiently prevented in a state in which the projections bite into the paint layer. With respect to the height of the projections, if it is too low, the co-rotation preventing effect is weak, and if it is too high, although co-rotation is prevented, looseness occurs. Therefore, a suitable height is required. For example, when a nut whose stipulated value of screw torque is 40 to 60 N • m is used, a height of the projection corresponding to this screw torque is suitably 0.03 to 0.12 mm.
[0011] Furthermore, another specific example of the co-rotation preventing process is a surface-roughening process increasing the frictional resistance with respect to the mounting member. The surface-roughening process is for increasing the degree of surface roughness, and with respect to the degree of surface roughness, for example, if co-rotation arises when the degree of surface roughness Ra is about 0.5 to 1.5, by carrying out a surface-roughening process such that Ra is 2.0 or more, the co-rotation can be prevented. As a method of a surface-roughening process, shot peening or the like may be suitably adopted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a longitudinal sectional view showing a ball joint relating to an embodiment of the present invention;
[0013] [0013]FIG. 2 is a side view of a ball stud structuring the ball joint relating to the embodiment of the present invention;
[0014] [0014]FIG. 3 is a sectional view taken along line III-III in FIG. 2;
[0015] [0015]FIG. 4A is a plan view of one portion of a seat surface portion of a ball stud on which a projection relating to the embodiment of the present invention is formed, and FIG. 4B is a side view of one portion of the seat surface portion thereof;
[0016] [0016]FIG. 5 is a transverse sectional view of a ball stud showing another embodiment of the present invention;
[0017] [0017]FIG. 6 is a graph showing the relationship between the height of the projection and a co-rotation generated torque relating to the embodiment of the present invention; and
[0018] [0018]FIG. 7 is a graph showing the relationship of a degree of surface roughness and a co-rotation generated torque relating to the embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Hereinafter, an embodiment of the present invention will be described with reference to FIG. 1 through FIGS. 4A and 4B.
[0020] [0020]FIG. 1 shows a ball joint used for a connection portion of a vehicle stabilizer. A ball joint 1 relating to the embodiment is formed such that a ball stud 10 and a pivotably-supporting member 20 universally pivotably-supporting the ball stud 10 are a main body, and is fixed to a plate-shaped mounting member 40 .
[0021] As shown in FIG. 2, at the ball stud 10 , a ball portion 12 is formed at one end portion of a cylindrical stud portion 11 , and a collar portion 13 is formed at intermediate portion in the axial direction of the stud portion 11 , and furthermore, a screw portion 14 is formed at the distal end side from the collar portion 13 of the stud portion 11 , that is, on the peripheral surface of the opposite side of the ball portion 12 . The pivotably-supporting member 20 is structured from a ball seat 21 and a housing 22 in which the ball seat 21 is press-fit and accommodated. As shown in FIG. 1, the ball seat 21 is a cylindrical shape having a bottom and having a collar portion 21 a at the upper end rim, and a spherical seat 21 b is formed at the inside thereof. The ball seat 21 is molded from a hard resin such as polyacetal, polybutylene terephthalate, or the like. The housing 22 also is a of cylindrical shape having a bottom and having a collar portion 22 a at the upper end rim. One end of a support bar 23 extending in the radial direction of the housing 22 is fixed to the outer peripheral wall of the housing 22 .
[0022] As shown in FIG. 1, the ball portion 12 of the ball stud 10 is slidably fitted together with the spherical seat 21 b of the ball seat 21 . In this way, the ball stud 10 is pivotably-supported universally, that is, so as to freely rotate in an oscillating manner and so as to freely rotate axially, around the ball portion 12 with respect to the ball seat 21 . Reference numeral 30 in FIG. 1 is an umbrella-shaped dust cover. The dust cover 30 is fixed by the end rim at the large diameter side thereof being sandwiched between the collar portion 21 a of the ball seat 21 and the collar portion 22 a of the housing 22 , and the end rim at the small diameter side thereof is anchored to the collar portion 13 of the ball stud 10 . The interior of the ball seat 21 is thereby covered.
[0023] As shown in FIG. 1, the ball joint 1 is fastened by sandwiching the mounting member 40 by the collar portion 13 of the ball stud 10 and a nut 50 by passing the distal end portion of the ball stud 10 on which the screw portion 14 is formed through a through hole 40 a formed in the mounting member 40 and by screwing the nut 50 with the screw portion 14 so that the ball joint is fastened to the mounting member 40 . In this fixed state, a ring-shaped seat surface portion 13 a of the collar portion 13 facing the screw portion 14 abuts the mounting member 40 . As shown in FIG. 2, a plurality of projections 15 preventing the ball stud 10 from co-rotating at the time of fastening the nut 50 are formed at the seat surface portion 13 a.
[0024] As shown in FIG. 3, the plurality of projections 15 (there are 6 projections in this case) are formed at uniform intervals along the outer peripheral rim of the seat surface portion 13 a, and are arranged radially on the whole. As shown in FIGS. 4A and 4B, the projection 15 is a triangular pyramid shape whose plane view is a longitudinally elongated isosceles triangle shape and whose side view is a right-angled triangle shape. When the projection is made to be the tallest and is viewed in plan view, the short base portion is along the circumference of the seat surface portion 13 a, and the distal end extends toward the axial center of the seat surface portion 13 a. With respect to the dimensions of the projection 15 , for example, when the screw portion 14 of the ball stud 10 is M 10 , the ball portion 12 has a diameter of 16 mm, and the outside diameter of the seat surface portion 13 a is 16.5 mm, the height of the projection 15 is about 0.03 to 0.12 mm, and the length thereof is about 2 mm.
[0025] In accordance with the above described ball joint 1 , as shown in FIG. 1, if the nut 50 is fastened in order to fix to the mounting member 40 , the plurality of projections 15 formed at the seat surface portion 13 a of the collar portion 13 of the ball stud 10 bite into the mounting member 40 , and in accordance therewith, the co-rotation of the ball stud 10 is prevented. When paint is applied to the mounting member 40 , the co-rotation is sufficiently prevented in a state in which the projections 15 bite into the paint layer. In the present embodiment, without using a new member to prevent co-rotation, prevention of co-rotation can be achieved by forming the projections 15 at the seat surface portion 13 a of the collar portion 13 . Accordingly, the co-rotation of the ball stud 10 can be reliably prevented without leading to an increase in the number of parts and the accompanying troublesomeness of assembly work.
[0026] Next, another embodiment of the present invention will be described with reference to FIG. 5.
[0027] In the present embodiment, as shown in FIG. 5, instead of forming the above-described projections 15 at the seat surface portion 13 a of the collar portion 13 , a surface-roughening process 16 is applied to the seat surface portion 13 a by a method such as shot peening or the like, and the degree of surface roughness is increased. In this way, if the seat surface portion 13 a is subjected to a surface-roughening process, the frictional resistance of the seat surface portion 13 a with respect to the mounting member 40 increases, and the co-rotation of the ball stud 10 at the time of fastening the nut 50 is prevented. It should be noted that, with respect to the degree of surface roughness of the seat surface portion 13 a, for example, if co-rotation occurs when the degree of surface roughness Ra is about 0.5 to 1.5, co-rotation can be reliably prevented by surface-roughening processing so that the Ra is 2.0 or more.
EXAMPLES
[0028] Next, examples of the present invention will be described.
[0029] [1] Forming of projections
[0030] The projections of the shape and the arrangement shown in FIG. 3 and FIGS. 4A and 4B were formed, while changing the height in a range of 0.01 to 0.16 mm, at a seat surface portion of a collar portion of a ball stud which is the same as the ball stud 10 shown in FIG. 2 and whose material was steel equivalent to S30C to S45C. The projections were formed by forging at the same time as the molding of the ball stud. As shown in FIG. 1, these ball studs were fastened to a mounting member by nuts, and the screw torque when co-rotation arose at the ball stud was investigated. It should be noted that the screw portion with which the nut was screwed was M 10 , and an electrophoretic coating of a cationic resin was applied at a thickness of 20±10 μm to the surface of the mounting member into which the projections bit.
[0031] [0031]FIG. 6 shows the relationship between the height of the projection and co-rotation generating torque. A specified value of the screw torque of an M 10 screw portion is 40 to 60 N • m, and it is known that it suffices to ensure about 0.03 mm as the height of the projection at which co-rotation does not arise even if the specified value of the screw torque is 60 N • m which is the upper limit. Furthermore, for safety, even if the screw torque is two times 60 N • m, that is, 120 N • m, the height of the projection at which co-rotation does not arise is about 0.12 mm. However, because there is a concern that if the height of the project is greater than that, the nut will loosen, the height of the projection in this case is appropriately 0.03 to 0.12 mm.
[0032] [2] Surface-roughening process
[0033] Instead of forming the projections, the seat surface portion of a collar portion of a steel ball stud (the screw portion was M 12 ), which was the same as the ball stud 10 shown in FIG. 2, was subjected to surface-roughening processing while varying the degree of surface roughness Ra in a range from about 0 to 5.0. These ball studs were fastened to the mounting member by nuts in the same way as described above, and the screw torque when co-rotation arose at the ball stud was investigated.
[0034] [0034]FIG. 7 shows the relationship between the degree of surface roughness and co-rotation generating torque. The specified value of the screw torque of the screw portion of M 12 is 80 to 100 N • m. It can be understood that, as a degree of surface roughness at which co-rotation does not arise in accordance therewith, it suffices to ensure an Ra of 2.0 or more. | A ball joint comprises a ball stud having a stud portion at a middle thereof, a ball portion and a screw portion at opposite sides of the stud portion, and a seat surface portion facing the screw portion between the respective portions, and a bearing member into which the ball portion is slidably fitted so as to universally pivotably-support the ball stud, so that the stud portion is inserted through a mounting member, and a nut is screwed with the screw portion projected from the mounting member, and the seat surface portion abuts and is fastened to the mounting member by fastening the nut to the mounting member. The seat surface portion abutting the mounting member is subjected to a co-rotation preventing process which prevents the ball stud from co-rotating along with the nut when the nut is fastened. | 5 |
RELATED APPLICATIONS
[0001] This is a divisional of U.S. Patent Application filed May 28, 2002, entitled “Fluoropolymer Flowmeter” and assigned Ser. No. 10/156,449, which in turn claims the benefit of the contents and filing date of U.S. Provisional Patent Application filed May 25, 2001, entitled “Injection Molded and Welded Fluoropolymer Flow Meters” and assigned Ser. No. 60/293,672, and Provisional Patent Application filed Mar. 15, 2002, entitled “Low Flow Rate Fluoropolymer Flowmeter” and assigned Ser. No. 60/364,774, with all of said applications being incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to fluid flowmeters, and more particularly, to a substantially unitary-bodied fluoropolymer flowmeter capable of employing various component and float configurations.
BACKGROUND OF THE INVENTION
[0003] Flowmeters are utilized in many different industries to measure and control the flow of various fluids. Flowmeters generally utilize moveable float members in the fluid flow stream for the measurement of pressure drops across an orifice in the fluid flow stream. These flowmeters generally have electrical circuits and readouts that provide highly accurate measurements of flow rates. Due to their complexity, reliability and maintenance are issues, as is cost. A mechanically simple and highly reliable flowmeter utilizes an upright tube that allows for visual gauging of volumetric flow rates through the monitoring of marked indicia on the sight flow tube itself, or other connection means. The sight tube will have a pair of fittings at each end of the sight tube for connection to and insertion into a fluid flow circuit. A “float” is denser than the fluid being measured, is visible through the sight tube, and rises up the tube as the flow rate increases. The flow rate is visually indicated by the position of the float in the sight tube. Typical floats are generally shaped as balls, spherical objects, and other non-elongate members designed to move freely in the sight tube or to be guided along a guide rod securely mounted within the sight tube. Such conventional float designs generally function sufficiently in measuring medium to high fluid flow rates through a flowmeter. However, in certain industries, such as semi-conductor processing, low and ultra-low fluid flow rates are often required during processing. The measurement of these reduced flow rates through a fluid flowmeter must be accurately indicated to ensure processing efficiency and precision.
[0004] Even known float assemblies in the industry having a generally elongate float, which are designed to meter low fluid flow rates, are deficient. Referring to FIG. 2 in particular, a prior art flowmeter 210 having a tapered elongate float 217 and sight tube 212 system is utilized wherein the float 217 is guided through guides 214 , 216 . This system is intended to meter low fluid flow rates. The float 217 comprises a tapered section 218 that ends approximately central to the float 217 at a ledge 222 . Lateral float movement is controlled with the use of bottom guides 216 and top guides 214 . The taper of the float 217 increases from one end proximate the guides 216 to the ledge 222 . As the float 217 is forceably moved upward with fluid pressure through the sight tube 212 , it progresses upward until the ledge 222 engages the top guides 214 . With a reduction in fluid flow, the float 217 returns downward until being stopped by the tapering effect of the tapered section 218 . Such a system has an innate drawback in that stopping of the float 217 with the tapered section 218 within the bore or channel of guides 216 can cause an undesirable wedging effect. This innate characteristic is particularly unacceptable when measuring low flow rates. Namely, the tapered section 218 can become measurably stuck within the guides 216 such that a higher level of flow is required to initiate forceable movement of the float 217 within the tube 212 . Since low flow rates are the focus of such a flowmeter, this can serve to decrease reliability and accuracy, especially for the periods of fluid flow prior to dislodging of the wedged float 217 . In fact, this may completely prevent fluid flow metering for ultra-low fluid flows through the flowmeter 210 .
[0005] In the processing of semi-conductor wafers into integrated circuits, highly corrosive, ultra-pure fluids, such as hydrochloric, sulfuric and hydrofluoric acid, are in extreme temperature ranges and are utilized. These fluids not only damage traditional flowmeter materials, but they additionally impose significant health risks for personnel exposed to the fluids during the manufacturing process. Moreover, the equipment and materials in contact with these ultra-pure fluids must not contaminate or add impurities to the fluids.
[0006] Thus, semi-conductor processing applications require flowmeter construction providing accurate fluid flow measurements at varying fluid flow rates, while at the same time utilizing highly inert materials that withstand the potential damaging effects of these corrosive fluids, that do not contaminate the fluids, and that tolerate the broad temperature ranges. Moreover, the design of such flowmeters must minimize fluid leakage pathways.
[0007] Prior art flowmeters have addressed the problems associated with the use of corrosive fluids in flowmeters by using highly inert corrosive-resistant plastics in the construction of components of the flowmeters. Fluoropolymers such as perfluoroalkoxy resins (PFA), polytetrafluoroethylenes (PTFE), and ethylenetetrafluoroethylenes (ETFE) are plastics that are suitable for use with these corrosive fluids. The translucent-transparency characteristics of thin-walled PFA is typically utilized in the construction of the sight tube of these flowmeters.
[0008] U.S. Pat. No. 5,672,832 (the '832 patent) is an example of a flowmeter device where fluoropolymers are utilized. This specific device discloses a fluoropolymer housing flowmeter that places two cavities in the flow tube region where pressure sensors are placed for accurately measuring fluid flow rates. The rectangular housing and cover for this invention are constructed of non-translucent PTFE and the cover is mounted to the housing with screws, with a gasket positioned in between the two in an attempt to minimize fluid leakage.
[0009] U.S. Pat. Nos. 5,078,004, 5,381,826, and 5,549,277 are examples of fluoropolymer flowmeters utilizing sight tubes where a limited portion of the flowmeter is made of PFA material. In such flowmeters, the centrally located sight tube can be machined from PFA, with additional fitting components machined from PTFE, or other non-translucent materials, which are connected directly to the ends of the sight tube, or connected in series with those parts that do have a direct association with the PFA sight tube. Generally, each of these components are attached to each other and/or the sight tube via threaded portions.
[0010] These currently available fluoropolymer flowmeter devices, whether they be conventional sight tube flowmeters or other flowmeters, contain disadvantages centering mainly around the materials used and the methods of assembly.
[0011] Generally fluoropolymers, particularly PTFE, are not conducive to injection molding processes. As a result, in the known commercial sight tube fluoropolymer flowmeters, such as the device shown in FIG. 1 , each component is machined to obtain the desired shapes, tolerances, and the requisite threaded connections. Machining adds very significant labor costs to the production of the devices and, to the extent possible, should be avoided. Moreover, multi-component flowmeter assemblies utilizing threaded portions present potential fluid leakage pathways. The possibility of fluid leakage is increased with each non-unitary connection between components. For instance, in FIG. 1 , the flowmeter 200 includes at least a first fitting 202 , and a second fitting 204 that are threadably attached, at threaded portions 208 , to the tapered sight tube 206 , thus increasing the potential for unacceptable leakage. Further, the sight tube 206 is likely constructed of translucent PFA, while the fittings 202 , 204 are constructed of a material such as PTFE.
[0012] Ideally, flowmeters, particularly those utilized in handling corrosive-caustic fluids, should have a minimum number of non-unitary connections that do utilize the process of threadingly joining molded flowmeter components, namely the fittings to the sight tube.
[0013] The manufacturing process for the so-called unitary-bodied flowmeters constructed of conventional plastics generally involves the affixation of a plug or cap to a body portion. The affixation processes known for these conventional plastic sight tube flowmeters involve adhesive bonding and ultrasonic welding. Ultrasonic welding involves vibrating or oscillating a first plastic component with respect to a second plastic component that it is in engagement with the first plastic component. Such welding is not effective for joining tubular end portions. Moreover, due to the “slippery” nature of fluoropolymers, forms of vibrating or oscillating bonding is not realistic. Similarly, adhesives do not work on fluoropolymers, and would only add potential contaminants which must be avoided in semi-conductor processing applications.
[0014] Although PFA is substantially more expensive then PTFE (perhaps 10-15 times as expensive) it is considered to have great advantages over PTFE. Namely, PFA is cleaner, providing less contaminants than PTFE. Further, and unlike PTFE, PFA can be injection molded and homogeneously joined with like materials.
[0015] Homogeneously joining by welding separate fluoropolymers components, such as PTFE, is essentially impossible. In comparison, PFA components may be welded together utilizing non-contact heating as disclosed in U.S. Pat. No. 4,929,293, assigned to Fluoroware, Inc., also the owner of the instant application. It is believed that these welding techniques have never, before this invention, been utilized in association with the manufacture of a fluoropolymer flowmeter.
[0016] All of the discussed prior art falls short of adequately addressing the unique accuracy, purity, and low fluid flow needs of the semi-conductor processing industry. The prior art does not address the need for coupling the benefits PFA offers in resisting corrosion with the advantages a unitary-bodied component construction advances with regard to leakage prevention and reduced manufacturing and assembly costs.
SUMMARY OF THE INVENTION
[0017] The embodiments of the flowmeter of the present invention substantially solve the problems innately present with conventional fluid flowmeters. These needs are addressed by introducing a corrosive-resistant flowmeter made of a material such as PFA where reliability and effectiveness are increased while manufacturing costs can be reduced in one embodiment by utilizing a unitary-bodied component construction. Further, the a functional component design that enables accurate and efficient readings and indications of reduced fluid flow rates.
[0018] In one embodiment, a sight tube flowmeter is formed of a plurality of fluoropolymer components welded together to form a unitary flowmeter body. The components can comprise a PFA upright sight tube having two end portions, a flow conduit extending therethrough and two fitting portions that are uniquely welded onto each end of the sight tube, and a fluoropolymer float device movable to various positions within the flow conduit depending on the flow level of the fluid flowing therethrough. The float device can be of conventional design or for those flowmeter embodiments where low fluid flow rates are to be measured, an elongate float can be utilized. The floats and, in particular, a designated portion thereof, are visible through the sight tube to provide visual indication of the position, and thus the flow rate of fluid flowing through the flowmeter. In addition, alternative embodiments include the implementation of the unique sight tube and elongate float design in conventional flowmeters not having a unitary-bodied configuration.
[0019] At least one of the fittings may include a valve assembly to control the flow rate of the fluid. The invention also includes the process of manufacturing the flowmeter, in particular the steps of injection molding PFA components and welding the PFA components to form a unitary flowmeter body. In one embodiment of the process the components are welded using a noncontact heater to melt the PFA portions to be welded, wherein the portions are then brought into contact with each other and held until the PFA cools and solidifies. A curing step involving baking at least one of the PFA flowmeter components on a jig, may also be added.
[0020] A feature and advantage of an embodiment of the invention is that the entire flowmeter body can be of a unitary construction. Threaded connections between the sight tube and the sight tube end connections are eliminated. This minimizes potential leakage pathways, lessens potential hazards to personnel, and lowers manufacturing costs.
[0021] A further feature and advantage of an embodiment of the invention is that machining of component parts of the flowmeter is substantially, or even entirely, eliminated. This, in turn, can lower labor and manufacturing costs, and the end cost of the flowmeter.
[0022] Yet another feature and advantage of an embodiment of the invention is that the body is manufactured entirely of PFA which is cleaner and exposes the metering process to less contamination. This is essential in the semiconductor processing field.
[0023] Still another feature and advantage of an embodiment of the invention is that the entire body can be measurably translucent. Translucent characteristics provide for increased visibility of the component positions such as a valve member and float, and provide increased visibility of any contaminants that may be present within any portion of the flowmeter.
[0024] A further feature and advantage of an embodiment of the invention is that it can be an injection molded flowmeter that is inert and chemically resistant to the chemicals utilized in semiconductor wafer processing.
[0025] Yet another feature and advantage of an embodiment of the invention is that the design of the elongate float coupled with the shape and construction of the conduit within the sight tube cam permit an increase in metering accuracy for low and ultra-low fluid flow rates through the flowmeter.
[0026] Another feature and advantage of an embodiment of the invention is that the sight tube and elongate float design of the present invention can be implemented in those conventional flowmeters that are not unitary-bodied to increase measurement of low and ultra-low fluid flow rates.
[0027] Still another feature and advantage of an embodiment of the invention is that the welding of multiple components or parts together to form a unitary-bodied flowmeter can increase the possibilities and efficiencies of adjusting and modifying the structural configuration of the three main weldable components of the flowmeter. Modifications can be efficiently focused on only those components where it is needed such that molding and manufacturing processes for the entire flowmeter are not unnecessarily disrupted or altered. For instance, design and functional changes can be narrowly directed to the sight tube and float assembly if desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a view of a prior art flowmeter;
[0029] FIG. 2 is cross-sectional view of a prior art float assembly employed in a prior art flowmeter;
[0030] FIG. 3 is a cross-sectional view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0031] FIG. 4 is a cross-sectional view of one embodiment of a valveless unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0032] FIG. 5 is a side view of one embodiment of a valveless unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0033] FIG. 6 is a an exploded view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0034] FIG. 7 is a cross-sectional view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0035] FIG. 8 is a cross-sectional view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0036] FIG. 9 is a cross-sectional view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0037] FIG. 10 is an exploded view of one embodiment of a unitary-bodied fluoropolymer flowmeter in accordance with the present invention;
[0038] FIG. 11 is a view of a mold for injection molding fluoropolymer flowmeter components;
[0039] FIG. 12 is a schematic view illustrating baking an injection-molded fluoropolymer component;
[0040] FIG. 13 illustrates an apparatus for non-contact welding fluoropolymer components;
[0041] FIG. 14 is a perspective view of a fluid flow rate calibration jig;
[0042] FIG. 15 is a perspective view of a fluid flow rate calibration jig.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] FIG. 3 shows one embodiment of a unitary-bodied flowmeter 12 in accordance with the present invention. The flowmeter can be a welded assembly of injection molded fluoropolymer plastic components, generally PFA components or fluoropolymers having translucent qualities, wherein at least two of the three main body components are joined through a compactable welding process. Other fluoropolymer plastics are also envisioned for component and part use in the flowmeters in accordance with the present invention. For example, but not for limiting purposes, PTFE, ETFE, and other plastics are envisioned. The translucent characteristics of the preferred fluoropolymers can vary in the degree to which it is translucent, such that translucent characteristics permit gauging of a float device within the sight tube, as will be discussed in detail herein.
[0044] Referring to FIGS. 3-10 , flowmeter 10 generally comprises the joining of at least two of three main body components into a unitary flowmeter body 12 . Unitary-bodied can mean the joining two of the three main body components to the third component through a weldment bond (discussed herein) such that two of components are initially molded as one piece. For instance, one molded piece could comprise of the second fitting 18 and sight tube 16 , with the first fitting 14 being later welded or otherwise joined with the available end of the sight tube 16 . It is preferred that at least one of the three main body components is constructed of a translucent fluoropolymer for preferred embodiments.
[0045] The three main body components are first fitting 14 , sight tube 16 , and second fitting 18 . Once each component is positionally joined to properly form the unitary flowmeter body 12 , as will be explained in detail, body conduit 20 is formed which provides a flow channel beginning with and running through first fitting 14 , continuing through sight tube 16 , and running through and out of the end of second fitting 18 .
[0046] First fitting 14 generally comprises an entering end 22 and an exiting end 24 . In one embodiment, these ends 22 , 24 are generally in a perpendicular relationship to each other. A first fitting conduit 26 defines an inner bore of some diameter within first fitting 14 , traveling along the longitudinal axis of first fitting 14 for the entire distance beginning with entering end 22 and ending with exiting end 24 . First fitting conduit 26 results in first fitting openings 28 at each end 22 , 24 of first fitting 14 . Known fittings, connectors, and other devices known to one skilled in the art for connecting to sight tubes and other components of flowmeters are envisioned for first fitting 14 .
[0047] In one embodiment, as shown in FIGS. 3-4 , sight tube 16 comprises a generally cylindrical tube with first fitting end 30 and second fitting end 32 . The sight tube 16 has a tube conduit 34 running through it so that an inner bore of some diameter generally larger than the inner diameters of first fitting conduit 26 and second fitting conduit 52 is defined. Tube conduit 34 traverses the longitudinal axis of sight tube 16 for the entire distance of sight tube 16 so that sight tube openings 42 are formed at each of the ends 30 , 32 . The diameter of tube conduit 34 can gradually taper the distance of the tube conduit 34 . It is preferred that the diameter at second fitting end 32 is larger than the diameter at first fitting end 30 . While preferred embodiments are generally cylindrical with visual gauging characteristics, other shapes and constructions for the tube 16 are envisioned without deviating from the unitary characteristic of the flowmeter in accordance with the embodiments of the present invention.
[0048] As shown in FIGS. 5-6 , the outer surface of sight tube 16 can comprise flow indicia 44 . This flow indicia 44 generally consists of molded or etched marks depicting specific volumetric flow rate information for use in visual gauging.
[0049] In another embodiment, as shown in FIGS. 7-9 , sight tube 16 can comprise a generally hourglass-shaped tube with a first fitting end 30 , and second fitting end 32 . Sight tube 16 has a tube conduit 34 running through it to permit fluid flow communication between the first fitting 14 and the second fitting 18 . The conduit 34 is generally divided into three fluid flow channels or conduits: an entry conduit 36 , an exit conduit 38 , and an intermediate narrowed channel 40 . The portion proximate the center of the hourglass sight tube 16 and the inner tube conduit 34 defines a division between the entry conduit 36 and the exit conduit 38 and defines the intermediate narrowed channel 40 . The intermediate narrowed channel 40 serves as the communication channel between the conduits 36 , 38 and is some size smaller in diameter and cross-section than conduits 36 , 38 . Preferably, the diameter of entry conduit 36 gradually tapers such that the diameter at the portion of the conduit 36 proximate the first fitting end 30 is larger than the diameter proximate the intermediate channel 40 . The diameter of the exit conduit 38 is substantially consistent along its length, with only a diameter increase or tapered effect at the end 32 , 38 connectable to and in communication with the second fitting 18 . Similarly, the diameter or cross-section of intermediate channel 40 is generally consistent along its entire length, but could be varied. Tube conduit 34 traverses the longitudinal axis of sight tube 16 for the entire distance of sight tube 16 through conduit/channels 36 , 38 , 40 such that a continuous fluid flow path is established and sight tube openings 42 are formed at each of the ends 36 , 38 .
[0050] As best shown in FIG. 10 , the outer surface of the hour-glass shaped sight tube 16 also comprises flow indicia 44 . This flow indicia 44 generally consists of molded or etched marks depicting specific volumetric flow rate information for use in visual gauging.
[0051] For each of the preferred embodiments, second fitting 18 generally takes the form of a T-shaped fitting comprising entering end 46 , exiting end 48 , and valve end 50 . Entering end 46 is generally perpendicular to exiting end 48 and valve end 50 with exiting end 48 and valve end 50 sharing a common linear plane, with the shared linear plane intersecting the linear plane of entering end 46 so that the longitudinal axis of entering end 46 is nearly positioned at the center of the distance between the far ends 48 , 50 . Second fitting 18 has a second fitting conduit 52 traversing the longitudinal axis of second fitting 18 so that an inner bore of some diameter is defined. Second fitting conduit 52 traverses the entire distance of entering end 46 , exiting end 48 , and valve end 50 so that second fitting conduit 52 begins at entering end 46 and traverses toward the herein described plane intersection where it opens into and is one continuous shared channel with the portion of second fitting conduit 52 traversing the entire distance between exiting end 48 and valve end 50 . Known fittings, connectors, and other devices known to one skilled in the art for connecting to sight tubes and other components of flowmeters are envisioned for first fitting 14 . In certain embodiments, such as the flowmeters shown in FIGS. 4-5 , regardless of the sight tube and float assembly configurations, the flowmeter 10 can be constructed without a valve device.
[0052] In those embodiments having a valve device, second fitting conduit 52 at valve end 50 can define valve member opening 54 . Valve member opening 54 can be internally threaded some distance from valve end 50 inward toward exiting end 48 . This threading is designed for receiving a threaded valve assembly 56 . Such valve devices are best shown in FIGS. 3 , and 6 - 9 .
[0053] Valve assembly 56 comprises valve shaft 58 , and valve top portion 60 . Valve shaft 58 comprises a first end portion 62 , a valve member 64 , and can have a threaded portion 66 . Valve top portion 60 affixes to the first end 62 via a valve aperture 68 in valve top portion 60 which traverses some longitudinal distance not equal to the entire length of the valve top portion 60 . In an embodiment having external threading, threaded portion 66 is capable of threadably engaging internal threading in second fitting 18 such that the assembly 56 , and particularly the valve member 64 , can be adjustably moved in and out of the opening 54 . Other means of moving such a valve member 64 in and out of such an opening known to one skilled in the art are also envisioned.
[0054] The valve member 64 portion can include a valve needle protrusion 70 or extension shaped for insertion in and out of compatible area of the opening 54 with the relative linear movement of the valve assembly 56 . The valve needle 70 can be tapered or non-tapered, depending on the sealing performance desired, and the particular manufacturing requirements or limitations.
[0055] Generally, in those flowmeters 10 utilizing a valve assembly, valve top portion 60 is affixed to valve shaft 58 via a snapping means, as shown best in FIGS. 3 , and 7 - 9 . The snapping means comprises the valve shaft 58 , valve shaft groove 72 , valve top portion 60 , and valve top groove 74 . Valve shaft groove 72 is located distal the valve needle 70 end of the shaft 58 , begins some distance inward from the end opposite to the valve needle 70 end, and travels the entire outer circumference of the shaft with the recess of valve shaft groove 72 recessed into the shaft 58 some distance. Valve top groove 74 is located at the end of valve aperture 68 and is designed to receive valve shaft groove 72 of valve shaft 58 so that the valve shaft 58 and valve top portion 60 become interlocked in a rotationally limiting manner.
[0056] Alternative embodiments can use other means of affixing valve top portion 60 to the valve shaft 58 . These alternative embodiments can include fasteners such as screws or bolts. Single piece molding of valve top portion and valve shaft portion together is also an available embodiment. As stated, yet other embodiments can exclude any valve assembly at all.
[0057] Various known or inventive float assemblies can be employed with the flowmeter of the present invention. For instance, a spherical float or an elongate float and corresponding assemblies can be employed without deviating from the spirit and scope of the present invention.
[0058] For those flowmeter embodiments utilizing a spherical float 78 , as shown in FIGS. 3-6 , float assembly 76 is contained within sight tube 16 . Such a float assembly 76 comprises spherical float 78 , guide rod 79 , and resting apertures 81 . Spherical float 78 further comprises a float bore 83 that intersects substantially the center of float 78 and defines the receiving channel for insertion of the guide rod 79 . The diameter of float bore 83 is some size larger than the outside diameter of guide rod 79 . Guide rod 79 is generally a small diameter cylindrical rod with a first and second end. The outside diameter of guide rod 79 is significantly smaller than the diameter of tube conduit 34 . Guide rod 79 centrally traverses the entire distance of the tube conduit 34 of sight tube 16 , traversing completely through float bore 83 . Guide rod 79 is rested securely in its final assembled position when the first and second ends of guide rod 79 travel into and rest within resting apertures 81 . Resting apertures 81 can be located within an area inside the first fitting conduit 26 and second fitting conduit 52 . The inside diameter of resting apertures 81 are some size larger than the outside diameter of guide rod 79 so that selective insertion and removal of guide rod 79 from resting apertures 81 is possible.
[0059] For those flowmeter embodiments utilizing an elongate float 80 , referring primarily to FIGS. 7-10 , float assembly 76 is within sight tube 16 at the completed assembly of flowmeter 10 . Float assembly 76 generally comprises an elongate float 80 , and at least one float guide stop 84 . The float 80 preferably has a circular cross-section, but can also take on a myriad of other shapes, such as triangular, rectangular, oval, variations thereof, and the like. The elongate float 80 is preferably tapered for some length of the float 80 . Generally, the float 80 is tapered such that the diameter or cross-section of the float 80 gradually increases until it reaches an integrated float flange 82 . The flange can have bores, notches, or like features to enable fluid flow through a portion of the flange 82 to control the movement sensitivity of the float 80 . While the flange 82 is generally cylindrical, it can take on various other shapes as well. In one embodiment the flange 82 is located at an end of the float 80 , as shown in FIGS. 8-10 . In another embodiment, the flange 82 is located proximate the center portion of the float 80 , but can be located anywhere along the length of the float 80 , as shown in FIG. 7 . The outside diameter, or the cross-section, of the float 80 at the widest or largest portion is substantially smaller than that of either conduit 36 , 38 but is minimally smaller than the width or cross-section of channel 40 .
[0060] The float guider 84 can take the form of at least one guide 86 and/or at least one guide stop 88 . The guides 86 can be rectangular, oval, circular, spherical or a myriad of other shapes. The guides 86 can include a plurality of bores to permit fluid flow, as shown in FIG. 10 . The guide stops 88 are preferably of a T-shaped cross-section and can also include a plurality of guide stop bores 92 to permit fluid flow, as best shown in the cross-section view of FIG. 9 . The T-shaped form is substantially defined by the extension of a guide stop protrusion 94 . The stop protrusion 94 can be of varying lengths. FIG. 9 shows an embodiment implementing a relatively long stop protrusion 94 . Mounting needs and locations for the guide stops 88 and a litany of other factors will influence the length. A receiving bore 96 is generally included which is some size larger than the diameter of the portion of the float 80 it is designed to receive. The receiving bore 96 generally traverses the longitudinal axis of the stop protrusion 94 to completely penetrate the guide stop 88 . The diameter of the stop protrusion 94 is generally smaller than the diameter or cross-section of the flange 82 such that contact or abutment of the flange 82 against the proximate end of the stop protrusion 94 will limit the upward movement of the float 80 within exit conduit 38 .
[0061] In one embodiment, as shown best in FIGS. 8-9 , there are a plurality of float guiders 84 within the sight tube 16 . In particular, two guides 86 having a guide bore 90 are fixed within the entry conduit 36 , and a single guide stop 88 , with or without a protrusion 94 , is fixed within the exit conduit 38 . Both guide/stops 86 , 88 can be fixed at the end of the corresponding conduits 36 , 38 , or fixed some distance inward of the ends 30 , 32 . Alternatively, there can simply be one guide 86 , with at least one bore shaped and located such that it is capable of receiving the float 80 and restricting lateral movement in much the same manner as if two guides were implemented. The flange 82 is preferably located at a region proximate one end of the float 80 with such an embodiment, with said end of the float 80 being greater in cross-section or diameter than the distal end. The largest diameter cross-section of the float 80 at the tapered end is still some size smaller than the diameter of channel 40 to facilitate free movement through the channel 40 . The diameter or cross-section of the flange is larger than that of the proximate portion of the float 80 to limit upward movement against the stop 88 , and the protrusion 94 in particular.
[0062] If there are a plurality of guides 86 , then they are fixedly spaced some distance from each other such that a guide channel 98 is created. The portion of the float 80 traveling within this channel distance is small enough so that it can move freely without binding or wedging, while at the same time limiting lateral movement of the float 80 within the entry conduit 36 .
[0063] In another embodiment, as best shown in FIG. 7 , a single guide stop 88 is utilized and fixed within the exit conduit 38 . Movement of the float 80 is significantly limited to a region within conduit 38 , and thus lateral movement within conduit 36 is not a concern, and a guide 86 may not be needed. Accordingly, the flange 82 is located some distance along the float 80 away from the ends. Preferably, the flange 82 is proximate the center region of the float 80 in such an embodiment. At a lower region of the float 80 , the tapering gets smaller as it moves away from the flange 82 , while the cross-section of the float 80 remains substantially constant for the region approaching the opposite end or upper region above the flange 82 . The tapered end below the flange 82 at its largest diameter is still some size smaller than the diameter of channel 40 . The non-tapered end of the float 80 in this embodiment is generally sized smaller than the receiving bore 96 of the guide stop 88 and can be moved in and out of the bore until stopped by contact with the flange 82 against the guide stop protrusion 94 .
[0064] While the elongate float 80 described herein has been described with a unitary-bodied flowmeter, the elongate float and sight tube components and configurations detailed are also envisioned for use with conventional flowmeters.
[0065] Referring generally to the processes shown in FIGS. 11-13 , a process of manufacture of one embodiment of the unitary-bodied flowmeter in accordance with the present invention involves the following steps: first, designated PFA, or similarly at least translucent fluropolymer, components used in the manufacturing of the flowmeter 10 are injection molded in a mold 100 with a retractable insert 102 . This injection molding process permits the construction and shaping of thin PFA tubular components in order to achieve the desired result with regard to component translucence, which is particularly important with respect to the sight tube 16 . Each of the three body components 14 , 16 , 18 can be molded separately to be welded as described herein, or at least two of the components can be molded as a single component to be welded with the final component.
[0066] Following the injection molding process, each designated PFA component is baked in an oven 103 at a temperature range of approximately 300° F. to 500° F., forming the PFA components into their final sizes and construction for joining to form the final unitary-bodied flowmeter 10 . The PFA components can shrink substantially during the baking process. This injection molding and baking can be adjusted greatly with various jigs and other manufacturing processes and tools. As stated, various component configurations and combinations can be implemented. Further, component 14 , 16 , 18 shapes and sizes can be altered or re-designed while still leaving the remaining components untouched. This allows focused re-configuration to reduce manufacturing costs. For instance, if the manufacturer is desirous of changing only the configuration of the sight tube 16 , such a change can be made without altering the configurations of the fittings 14 , 18 .
[0067] Referring to FIG. 13 , once the components have been properly injection molded and baked, final joining of the components into a unitary-bodied fluoropolymer flowmeter 10 is possible. Generally, at least two of the three main body components, 14 , 16 , 18 are non-contact welded together creating a weldment bond 104 . For instance, first fitting end 30 of sight tube 16 can be non-contact welded to exiting end 24 of first fitting 14 , creating a weldment bond 100 . Further, second fitting end 32 of sight tube 16 can be non-contact welded to entering end 46 of second fitting 18 . Details of such non-contact welding are found in U.S. Pat. No. 4,929,293 which is incorporated herein by reference. In addition, other non-contaminating techniques and methods of bonding the fluoropolymer components known to one skilled in the art can be employed as well.
[0068] Referring primarily to FIGS. 13-14 , the non-contact welding and manufacturing process for one spherical float 78 embodiment is shown. Float assembly 76 for the spherical float 78 embodiment is calibrated prior to the joining or welding of second fitting 18 to a previously joined assembly of first fitting 14 and sight tube 16 . Spherical float 78 is positioned in the juncture of first fitting 14 and sight tube 16 so that float 78 rests at the resting aperture 81 integral to first fitting conduit 26 . A calibration guide rod 112 is positioned through the float into the guide rod aperture 81 of first fitting 14 so that it extends upwardly. A calibration fitting 114 engages the top opening of sight tube 16 . The calibration guide rod 112 is received by the fitting 114 . The calibration fitting 114 is temporarily sealingly attached to sight tube 16 and is removed upon completion of the calibration process.
[0069] Fluid, typically water, is forced into entering end 22 of first fitting 14 , traveling through first fitting conduit 26 and into the tube conduit 34 of sight tube 16 where it forces float 78 up guide rod 112 some distance depending on the applied flow rate. Spherical float 78 is replaced with others of different size, shape, or weight until the desired flow readings are obtained consistent with actual flow rates provided by calibration circulator 106 .
[0070] Once calibration readings are ideal, the calibration fixture 114 and guide rod 112 are removed, guide rod 79 is inserted through aperture 81 in place of the calibration guide rod 112 , and aperture 81 is sealed by heating and pinching the boss 110 .
[0071] Referring primarily to FIGS. 13 and 15 , the non-contact welding and manufacturing process for an elongate float 80 embodiment is shown. Assembly 76 is generally calibrated prior to the joining of second fitting 18 to the already joined assembly of first fitting 14 and sight tube 16 .
[0072] Fluid, typically water, is forced into entering end 22 of first fitting 14 , traveling through first fitting 14 and into sight tube 16 where it forces float 80 up body conduit 20 . Float 80 is replaced with others of different size, shape, or weight until the desired flow readings are obtained consistent with actual flow rates provided by calibration circulator 106 . Various low and ultra-low rates can be easily metered with such precision calibration. Once calibration readings are ideal, the calibration fixture is removed. In addition, aperture 108 is generally sealed by heating and pinching the boss 110 .
[0073] With calibration complete, on either float assembly embodiments, the next step generally consists of joining second fitting 18 and sight tube 16 by non-contact welding second fitting end 32 of sight tube 16 to entering end 48 of second fitting 18 . However, as stated herein, it is envisioned that non-contact welding could be implemented to attach or bond only two of the three main body components 14 , 16 , 18 . Completion of the assembly and calibration processes results in the final flowmeter body 12 assembly with body conduit 20 consisting of a continuous flow channel beginning with entering end 22 of first fitting 14 , continuing through sight tube 16 , and running through and out of exiting end 48 opening of second fitting 18 .
[0074] During operation of the flowmeter 10 having a generally elongate float 80 , fluid is introduced into entering end 22 of first fitting 14 . As the fluid traverses through the conduit 26 into conduit 34 it puts anti-gravitational pressure on float 80 , which has a gravitational bias. The vertical force of the fluid consequently moves float 80 upward closer to second fitting 18 . In preferred elongate float embodiments having a flange, the flange 82 begins in an initial seat or rest position against the region where the upper portion of channel 40 and the lower portion of conduit 38 join. In this initial seated position, the flange 82 substantially closes off fluid communication through channel 40 , and thus measurably restricts fluid from entering into conduit 38 from conduit 36 . In conventional flowmeter float designs, a relatively significant amount of vertical fluid force is needed to counter the gravitational bias of the float. In the present invention, however, the fluid flow required to move the float 80 is significantly reduced. This is possible because of the initial closed position of the flange 82 against the channel 40 and the narrowing distance provided by the narrow channel 40 . Fluid force builds up rather easily behind the flange 82 since there is substantially no room between the float 80 and the proximate walls of the channel 40 . This reduced fluid travel space coupled with the inability of the fluid to travel past the blockage created by the flange 82 creates a highly sensitive configuration where fluid metering of low fluid flow is possible. Fluid pressure behind the flange 82 and channel 40 is easily created despite low or ultra low fluid flows.
[0075] As the low flowing fluid builds up within the channel 40 and against the flange 82 , the float 80 will move correspondingly. Because of the relative narrowness of the channel 40 , and the reduced size of conduit 38 in comparison to conduit 36 , fluid pressure on the float 80 will continue despite consistent low or ultra-low fluid flow rates within the body conduit 20 even after the flange 82 has moved some distance upward beyond its initial seated position against the opening of channel 40 . Once the vertical force of the fluid is equal to that of the gravitational bias of float 80 , vertical movement will stabilize. If not, movement of the float 80 upward will continue until the flange 82 abuts the guide stop 88 , or protrusion 94 . The distance between the flange 82 in its resting position, and the protrusion 94 can be adjusted by altering the length of the conduit 38 , adjusting the length of the protrusion 94 , the fixed location of the guide stop 88 , and like techniques and configurations. Indications of the fluid flow rates can be measured by metering a portion of the float 80 against the marked or etched indicia 44 on the sight tube 16 . Preferably, flow rates can be measured according to the alignment of the flange 82 in relationship to the indicia 44 . Needed adjustments to fluid flow rates can be made based on the obtained flow readings.
[0076] During operation of the flowmeter 10 employing a generally spherical float 78 , fluid is introduced into entering end 22 of first fitting 14 . As the fluid traverses through the body conduit 20 into tube conduit 34 it puts and anti-gravitational pressure on float 78 which has a gravitational bias. The vertical force of the fluid consequently moves float 78 along guide rod 79 , moving float 78 closer to second fitting 18 . Once the vertical force of the fluid is equal to that of the gravitational bias of float 78 , vertical movement will stabilize. Flow rate readings during this stabilization period can be made according to flow indicia 44 . Needed adjustments to fluid flow rates can be made based on the obtained flow readings.
[0077] Although the invention hereof has been described by way of example of preferred embodiment, it will be evident that other adaptations and modifications may be employed without departing from the spirit and scope thereof. The terms and expressions employed herein have been used as terms of description and not of limitation; there is no intent of excluding equivalents and it is intended that the description cover any and all equivalents that may be employed without departing from the spirit and scope of the invention. | In one embodiment, a sight tube flowmeter is formed of a plurality of fluoropolymer components welded together to form a unitary flowmeter body. The components can comprise a PFA upright sight tube having two end portions, a flow conduit extending therethrough and two fitting portions that are uniquely welded onto each end of the sight tube, and a fluoropolymer float device movable to various positions within the flow conduit depending on the flow level of the fluid flowing therethrough. The float device can be of conventional design or for those flowmeter embodiments where low fluid flow rates are to be measured, an elongate float can be utilized. The floats and, in particular, a designated portion thereof, are visible through the sight tube to provide visual indication of the position, and thus the flow rate of fluid flowing through the flowmeter. In addition, alternative embodiments include the implementation of the unique sight tube and elongate float design in conventional flowmeters. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for measuring a lipid hydroperoxide at a lipid class level.
2. Description of the Related Art
Lipid peroxides are generally produced when molecular oxygen, active oxygen, or a free radical acts on an unsaturated fatty acid. The unsaturated fatty acid is oxidized by introducing oxygen molecules into double bonds. This oxidation reaction is called autoxidation. When this peroxidation reaction occurs, a cis type double bond site is converted into a conjugated double bond. Therefore, a hydroperoxide type lipid peroxide having a conjugated double bond is produced.
Oxygen molecules are directly introduced into saturated and unsaturated fatty acids in a photosensitized oxidation reaction. In this case, lipid hydroperoxides with and without a conjugated double bond are produced. A lipid hydroperoxide as a primary product derived by oxidation produces secondary oxides in decomposition and polymerization reactions.
Analysis of lipid peroxides in food and biological samples is based on colorimetry of hydroperoxides in total lipids or of secondary oxidation products. However, lipids have different properties and functions. In order to examine the existing forms and physiological meanings of lipids in food and living organisms or study a detailed mechanism of lipid oxidation, lipid peroxide levels must be analyzed in units of lipid classes (e.g., phosphatidylcholine hydroperoxide and phosphatidylethanolamine hydroperoxide as phospholipid classes).
The phospholipid is a component of a membrane of a living organism and is most important as a functional lipid for forming a micell with protein. The phospholipid easily changes since it contains large amounts of highly unsaturated fatty acids such as an arachidonic acid. The arachidonic acid serves as a precursor of many physiological active materials, e.g., as a precursor of prostanoids which exhibit strong hormonic effects. It is very important to analyze hydroperoxides of phospholipids containing large amounts of arachidonic acid for studying various diseases and geriatric diseases. Therefore, a strong demand has arisen for establishing a method of fractionation measurement of an amount of a hydroperoxide of, e.g., a glycerophospholipid including phosphatidylcholine as a main phospholipid.
In a conventional high performance liquid chromatography (HPLC)-ultraviolet absorption method, a hydroperoxide and a hydroxy derivative as its reduced product have the same retention time and the same peak (234 nm) of conjugated diene. It is therefore difficult to discriminate the hydroperoxide from its reduced product, a hydroxy derivative, and hence to accurately measure the hydroperoxide. In addition, the ultraviolet absorption method is adversely affected by an unoxidized lipid.
SUMMARY OF THE INVENTION
The present invention is mainly directed to solve a problem posed by the fact that a hydroperoxide and its hydroxy derivative have the same retention time and the same absorption peak to cause a difficulty in measuring only the hydroperoxide.
It is an object of the present invention to provide a method and apparatus for measuring a lipid peroxide in which a lipid sample is separated into lipid class levels, and a lipid hydroperoxide contained in the lipid classes is accurately measured.
A method according to the present invention comprises the steps of: separating a lipid sample into each of lipid classes by liquid chromatography; mixing a luminescent reagent with each of the separated lipid classes, thereby reacting the luminescent reagent with a lipid hydroperoxide contained in the lipid class; and optically measuring light produced by the reaction by a photodetecting means.
An apparatus according to the present invention comprises: liquid chromatography means for separating a sample into lipid classes; mixing means for mixing a luminescent reagent with each of the separated lipid classes to react the luminescent reagent with a lipid hydroperoxide contained in the lipid class; and photodetecting means for detecting light produced by the reaction.
According to the present invention, the sample is separated into the lipid classes by liquid chromatography, the luminescent reagent is mixed with the separated lipid class. The luminescent reagent reacts specifically with the lipid hydroperoxide if present in the lipid class, and emits light corresponding to the amount of the hydroperoxide contained in the classified lipid detected by the photodetecting means. Therefore, the hydroperoxide in each of the lipid classes can be accurately measured by detecting the emitted light.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an apparatus for measuring a lipid peroxide according to an embodiment of the present invention;
FIGS. 2 and 3 are plan views showing flow cells, respectively;
FIGS. 4 to 7 are graphs showing measurement results;
FIG. 8 is a graph showing a detected emission amount; and
FIG. 9 is a view showing an apparatus for measuring a lipid peroxide according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention combines a liquid chromatography with an emission spectroanalysis utilizing a luminescent reagent which specifically reacts with a lipid hydroperoxide to analyze the hydroperoxide. Lipid hydroperoxides in a very small amount, e.g., on the order of nmols contained in several to several tens of microliters of a sample is separated into lipid class levels and can be easily measured.
Briefly, a sample is fed to a high performance liquid chromatography. Each class of compounds separated by the liquid chromatography is monitored by an ultraviolet absorption detector, and at the same time a hydroperoxide in each monitored peak is reacted with a salt or hydroxide of a transition metal which produces a cation having a valency of 2, a complex of a transition metal having a valency of 2, a heme, a heme peptide, a heme protein, or a heme enzyme. The resultant active oxygen and oxygen radicals react with a luminescent substance, and light emitted by this reaction is optically measured.
FIG. 1 shows a measuring apparatus according to an embodiment of the present invention.
Referring to FIG. 1, high performance liquid chromatography (HPLC) comprises liquid feed pump 2 for feeding elution solvent 1, injector 4 for injecting sample 3 into the fed elution solvent (eluant), and column 5 for receiving the elution solvent mixed with the sample fed by injector 4. Ultraviolet absorption detector 6 is arranged at an elution portion of column 5 to detect ultraviolet absorption of each component eluted according to an adsorption capacity of an adsorbent in column 5. A luminescent reagent 8 is injected by liquid feed pump 7 into each of the components passing through ultraviolet absorption detector 6. Each component injected with the luminescent reagent 8 is supplied to flow cell 9. A photoelectron multiplier of chemiluminescence detector 10 of a single photoelectron count type opposes flow cell 9. Chemiluminescence detector 10 detects light from each component passing through flow cell 9. Detection results of chemiluminescence detector 10 and ultraviolet absorption detector 6 are recorded by recorder 11 comprising, e.g., a pen recorder.
Flow cell 9 has an internal volume of, for example, about 60 microliters and is made of a quartz glass tube or transparent Teflon tube.
FIGS. 2 and 3 show structures of flow cell 9. The flow cell in FIG. 2 has linear tube 20, while the flow cell in FIG. 3 has spiral tube 20. Although the straight tube has low detection sensitivity, it has high peak resolution. To the contrary, the spiral tube has good detection sensitivity, but it has low peak resolution.
Examples of the absorbent in column 5 in HPLC are chemically bonded silica gel, hydrophillic polymer gel, silica gel, polysaccharide gel, polystyrene gel, a polystyrene gel derivative, and a polysaccharide gel derivative. Column 5 is preferably an ODS (octadecylsilane)-treated reverse phase column treated with octadecylsilane or a normal phase silica gel column.
Examples of a catalyst acting on a lipid hydroperoxide to produce active oxygen species such as active oxygen or oxygen radicals are: a transition metal salt which produces a cation having a valency of 2 (e.g., ferrous chloride, ferrous sulfate, potassium ferricyanide, each of which produces Fe 2+ ; manganous chloride or manganous sulfate, each of which produces Mn 2+ ; or cobalt chloride or cobalt sulfate, each of which produces Co 2+ ); a hydroxide of the transition metals described above; a complex of a transition metal having a valency of 2 (e.g., Fe II -porphyrin complex); a heme protein (e.g., cytochrome C, hemoglobin, or myoglobin); a heme peptide (e.g., a compound obtained by decomposing a heme protein by a protease such as chymotrypsin or trypsin); and a heme enzyme (e.g., horseradish peroxidase or prostaglandin peroxidase).
A preferable catalyst compound is a heme protein, a heme peptide, or a heme enzyme. Most usually, the heme protein such as cytochrome C is used due to easy handling. The concentration of the catalyst compound can fall within the range of 0.1 μg/ml to 1,000 μg/ml and usually falls within the range of 1 μg/ml to 200 μg/ml. For example, best luminous efficiency can be obtained when the concentration is about 10 μg/ml for cytochrome C, about 120 μg/ml for cytochrome C heme peptide; and about 10 μg/ml for horseradish peroxidase.
The luminescent substance is not limited to a specific one, provided it reacts with active oxygen or an oxygen radical to emit light. Examples of such a compound are: polyhydroxyphenols (e.g., pyrogallol and perprogalline); a phthaladine derivative (e.g., luminol or isoluminol); an indol derivative (e.g., indoleacetic acid, skatole, or tryptophan); a thiazolidine derivative (e.g., Cypridinacea luciferin or lophine); an acrydine derivative (e.g., lucigenine), an oxalic acid derivative (e.g., bistrichlorophenyloxalate); and a 1,2- dioxa-4,5-azine derivative. The concentration of the luminescent substance varies depending on the compound used. The concentration is preferably 0.1 μg/ml or more. When luminol is used, its concentration is most preferably 1 μg/ml.
Examples of the lipid hydroperoxide to be detected are a hydroperoxide of a saturated fatty acid (e.g., palmitic acid hydroperoxide, stearic acid hydroperoxide, and their ester derivatives); a hydroperoxide of an unsaturated fatty acid (e.g., oleic acid hydroperoxide, linoleic acid hydroperoxide, linolenic acid hydroperoxide, arachidonic acid hydroperoxide, and their ester derivatives); a hydroperoxide of a glycerolipid (e.g., triacylglycerol hydroperoxide, glycerophospholipid hydroperoxide, glyceroglycolipid hydroperoxide); a hydroperoxide derived from food or a living organism component (e.g., a hydroperoxide derived from a serum lipid or edible oil or fat, a hydroperoxide derived from a lipoprotein, and a hydroperoxide contained in biotissue or fish or animal meat).
When the above measuring apparatus is used, measurement is preferably performed in a weak basic solution of a luminescent reagent such as a heme protein and luminol. When the reagent solution has a pH value of 9 to 10, good results can be obtained. A buffer for providing the above properties is a borate buffer (H 3 BO 3-- KOH), a carbonate buffer (Na 2 CO 3-- NaHCO 3 ), a glycine buffer (NH 2 CH 2 COOH--NaOH), or the like. The borate buffer is most preferable.
In order to prevent oxygen dissolved in the luminescent reagent solution from interfering analysis of a very small amount of hydroperoxide, the luminescent reagent solution is desirably purged with an inert gas to remove oxygen to obtain a stable measurement value. Examples of the inert gas are nitrogen gas and argon gas.
The concentration of the lipid hydroperoxide in lipid sample is calculated based on a calibration curve. The calibration curve can be formed by using a material selected from methyl linolate hydroperoxide, arachidonic acid hydroperoxide, phosphatidylcholine hydroperoxide, phosphatidylethanolamine hydroperoxide, and triacylglycerol hydroperoxide.
The present invention will be described in more detail by way of examples below.
A measurement sample was a phosphatidylcholine hydroperoxide prepared by photosensitized oxidation of egg-yolk phosphatidylcholine, using methylene blue. Column Elution Solvent:
Chloroform-methanol (1: 9 V/V (volume ratio); flow rate: 1.1 ml/min)
Column Elution Solvent Feed Pump 2: 880-PU pump available from Nihon Bunko K.K.
Sample Injector 4: VMD-EIE sample injector available from Shimamura Keiki Seisaku-Sho
Column 5: TSK-Gel silica 60 column (5 μm, 250 ×4.6 mm) available from Toyo Soda Kogyo K.K.
Ultraviolet Absorption Detector: UVIDEC-100-III UV detector available from Nihon Bunko K.K.
Luminescent Reagent: 50 mM Borate buffer (pH 9.3) dissolving cytochrome C (1 μg/ml) and luminol (10 μg/ml)
Luminescent Reagent Liquid Feed Pump 7: KHD-52 pump available from Kyowa Seimitsu K.K.
Chemiluminescence Detector: Chemiluminescence analyzer OX-7 available from Tohoku Denshi Sangyo K.K.
Recorder 11: SEKONIK SS-250F 2-pen recorder
FIG. 4 shows analysis results of phosphatidylcholine hydroperoxide (PCOOH) as a sample by using the measuring apparatus described above. Peaks A of PCOOH are detected on a chromatogram by ultraviolet absorption detector 6 and chemiluminescence detector 10.
FIG. 5 is a graph showing an analysis result when hydroxyphosphatidyl choline (PCOH) obtained by reducing PCOOH by sodium borohydride is used as a sample. Peak B detected by ultraviolet absorption detector 6 is not detected by chemiluminescence detector 10. By utilizing chemiluminescence detector 10, only the hydroperoxide can be specifically detected. This peroxide cannot be distinguished by ultraviolet absorption detector 6.
FIG. 6 shows a chromatogram when a mixture of PCOOH and phosphatidylethanolamine hydroperoxide (PEOOH) is used as a sample. Peak D of the PCOOH can be properly separated from peak C of the PEOOH. These peaks are detected by chemiluminescence detector 10. Therefore, when a phospholipid sample is analyzed, each of the hydroperoxides in the sample can be separately and specifically detected and differentiated from each other.
FIG. 7 shows a chromatogram when a mixture of unoxidized phosphatidylcholine (PC) and unoxidized phosphatidylethanolamine (PE) is used as a sample. Peak E corresponds to unoxidized PE, and peak F corresponds to unoxidized PC. As is apparent from FIG. 7, the unoxidized lipids are not detected by chemiluminescence detector 10 at all. Note that ultraviolet absorption detector 6 also detects undesirably the unoxidized lipids, and peaks E and F appear on the chromatogram.
According to the measuring method using the above measuring apparatus, lipid hydroperoxides can be specifically detected and measured.
FIG. 8 shows a calibration curve for measuring an amount of PCOOH by the measuring apparatus of the invention. Referring to FIG. 8, the emission amount corresponding to the peak area is plotted along the ordinate, and the concentration of the PCOOH is plotted along the abscissa. The concentration of the PCOOH is proportional to the emission amount in the range of 7 nmol of hydroperoxide-O 2 to 140 nmol of hydroperoxide-O 2 . A minimum detection amount of PCOOH is 7 nmol of hydroperoxide-O 2 .
FIG. 9 shows a measuring apparatus according to another embodiment of the present invention. The same reference numerals as in FIG. 1 denote the same parts in FIG. 9, and only different parts will be described below.
In this embodiment, detection output signals from ultraviolet absorption detector 6 and chemiluminescence detector 10 are supplied to coincidence circuit 21. Coincidence circuit 21 compares a detection result of ultraviolet absorption detector 6 with a detection result of chemiluminescence detector 10, i.e., peak positions detected by detectors 6 and 10. A detection result is supplied to data processor 22 comprising a microcomputer or the like. When a coincidence output is generated by coincidence circuit 21, the microcomputer determines that the lipid hydroperoxide has been detected, and a measurement result can be displayed and easily checked.
Since the lipid hydroperoxide can be specifically detected by chemiluminescence detector 10, ultraviolet absorption detector 6 need not always be used. Detector 6 may be used as needed.
Various changes and modifications may be made within the spirit and scope of the invention.
According to the present invention as described above, a lipid sample is separated into lipid classes by a liquid chromatography. A luminescent reagent is mixed with each of the lipid classes and reacted with the lipid hydroperoxide to emit light. The separated hydroperoxide can be detected by a photodetecting means. Therefore, the lipid hydroperoxide contained in the lipid classes can be accurately and properly measured. | A method and apparatus for measuring a lipid peroxide, in which a sample containing lipids is subjected to a liquid chromatography to separate the lipids into lipid classes. The lipid classes are brought into contact with a luminescent reagent which specifically reacts with a lipid hydroperoxide contained in the lipid classes to generate a light in an amount corresponding to a content of the hydroperoxide. The light is optically detected by a photodetector. | 6 |
This invention is concerned with a method of printing articles and printed articles produced by that method.
The invention is particularly although not exclusively concerned with a method of printing articles by transfer of a printing medium from a substrate onto an article to be printed, the article having a planar or contoured surface.
BACKGROUND OF THE INVENTION
Although at present complex multi-coloured prints may be applied quite readily to planar surfaces by such printing techniques as offset, lithographic, flexographic, screen printing and the like, there is no satisfactory method for printing of contoured articles wherein a high degree of accuracy is required.
Three dimensional topographical maps for use by government mapping departments, forestry departments, mining departments and military forces and the like require precisely located markings of contour lines, roads, railway tracks, rivers, streams, vegetation areas and the like in up to five or even more different colours. While the markings on such three dimensional contour maps may be produced quite satisfactorily by hand such manual marking is far too slow and expensive for high volume production.
It has been proposed to produce large quantities of three dimensional topographical contour maps by screen printing the required indicia or markings on a planar sheet of thermoplastics material and then vacuum forming the printed sheet in a contoured mould. This process is not satisfactory in that the varying degrees of stretching that occur in the heated sheet as it is drawn into cavities of varying depth cause distortion in the print with resultant misalignment of the indicia or markings with their intended position on the surface of the contoured map. In an endeavour to alleviate this problem computer calculated distortions are incorporated into the planar print with a view to compensating for the distortions which might otherwise occur during the vacuum forming process.
Although the pre-distortion of the printed indicia does to some extent improve the finished product, printed contour maps of this kind are inherently inaccurate. Differing levels of resident stress in the thermoplastic sheets combined with minor differences in the properties of the batches of thermoplastics material cannot be calculated and thus compensated for. In addition slight differences in moulding conditions such as pre-heat temperature of the sheet plastics material, mould temperatures and the like effectively prevent consistent manufacture of precisely marked three dimensional contour maps by this process.
SUMMARY OF THE INVENTION
It is an aim of the present invention to provide a reproducible method for precise printing of contoured articles.
It is a further aim of the invention to overcome or alleviate the difficulties associated with prior art methods for printing three dimensional contour maps and so provide accurately printed three dimensional contour maps produced by the method according to the invention.
It is yet a further aim of the invention to provide a novel method of transfer printing on moulded articles.
According to one aspect of the invention there is provided a method applying indicia to an article comprising the steps of:
applying to a sheet-like substrate a transferable print medium in the form of indicia to be transferred to the surface of an article;
supporting the sheet-like material against a support surface; and,
bringing into contact with said transferable print medium the surface of an article to be printed under conditions whereby said indicia is transferred to the surface of said article.
Suitably said sheet-like substrate comprises a flexible membrane, preferably a resiliently flexible membrane.
Most preferably said flexible membrane is comprised of an elastomeric polymer.
The print medium may suitably comprise a paint, ink or like medium which is adapted for application onto said substrate by any suitable printing process.
Preferably said print medium is adapted for preferential adhesion to the surface on an article to be printed.
The support surface may comprise any suitable surface, preferably an exposed surface of a female mould, or it may comprise the surface of an article to be printed. Most preferably said exposed surface is contoured.
If required lubricating means may be provided between said support surface and said sheet-like substrate to facilitate positioning of said sheet-like substrate in a predetermined position relative to said support surface. Preferably said sheet-like substrate is retained against said support surface under the influence of a reduced atmospheric pressure. Alternatively the membrane may be retained by a positive air pressure above the membrane.
In order that the invention may be more clearly understood a preferred embodiment of the invention will now be described with reference to the accompanying drawing.
DETAILED DESCRIPTION OF THE DRAWINGS
The sole FIGURE of the drawing is a cross-sectional view through a mould useful in practicing the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the initial stages of manufacture of a three dimensional topographical contour map it is first necessary to produce a model to the required scale. Such a model is constructed by skilled cartographers according to conventional techniques and may for example be constructed on a rigid base using a curable or hardenable modelling composition or a paraffin wax.
A female mould is then prepared from the model--again by conventional techniques and, if required, the mould may include perforations or venting ports communicating with the support surface to enable evacuation of air entrapped between the sheet-like substrate and the support surface.
Convenient techniques may include spark etching techniques to produce a metal mould or casting a mould with a hardenable compound such as aluminium powder filled epoxy or polyester resins.
A print substrate in the form of a thin rubber latex membrane was then prepared by casting onto a planar surface and allowing the membrane film to cure. The membrane may however be made by any suitable process.
In the present case the latex membrane measured 1 metre in area and was 0.05 mm in thickness.
The latex membrane print substrate was then placed on the platen of a silk screen printing bed and smoothed out to remove wrinkles and air bubbles. Indicia in various colours representing contour lines, roads, railway tracks, rivers, townships were then sequentially printed onto the print substrate in such a manner as to cause the required visual features of the print to be in contact with the membrane.
For example on a first print run a black printing ink is employed with an appropriate screen to apply to the substrate indicia markings corresponding to roads, tracks, railway tracks and the like. The printed indicia is then allowed to cure at least partially to achieve a "touch-dry" surface.
The preferred printing ink for this embodiment of the invention is an "In-mould lacquer" of the type used in polyurethane reaction injection moulding (RIM) techniques. This lacquer is designed to be applied to the inner surface(s) of a mould cavity prior to injection of the polyurethane components. This material does not require the use of an external mould release agent since a mould release agent incorporated in the lacquer provides sufficient release properties from the mould surface. Usually such a lacquer is applied to a heated mould (150-160 degrees F.) and allowed to cure at least partially under the influence of heat from the mould. When the injected polyurethane components react inside the mould, the lacquer chemically bonds to the moulded article and forms a decorative surface finish to the article. This technique is utilized to apply a single colour all over finish to a polyurethane article produced by a RIM process.
After the first application of screen printed indicia in say black ink (lacquer) to represent details such as roads, buildings, printed names etc., other coloured indicia are subsequently applied e.g. blue rivers and waterways and brown contour lines.
The final print pass represents the major background colour e.g. green for vegetation and the finished print has the appearance of a conventional two dimensional map. Alternatively the order of printing may be in the reverse order however, it is important in this aspect of the invention that the print has substantially the same visual appearance both at its exposed surface and at the interface between the print and the membrane substrate to enable subsequent positioning on a surface to be printed.
When the print is complete the membrane substrate is removed from the print platen and positioned over the previously prepared mould. To facilitate handling of the membrane substrate it may be supported about its periphery in a frame.
In the drawings, the surface of the mould 1 is lightly coated with a lubricating composition such as glycerine or the like and the printed substrate 2 is then brought into contact with the mould surface. The mould 1 is located in the lower half 3 of a RIM mould 4 and is sealed about its peripheral edge 5 against the inner wall 6 of the lower mould half 3. The mould 1 includes a plurality of fine passageways 7 extending between the upper and lower surfaces 8 and 9 respectively of the mould 1. The passageways 7 communicate with a plenum 10 which in turn is connected to a vacuum pump or the like to evacuate the air space between the membrane 2 and the upper surface 8 of the mould 1. To ensure a complete evacuation of air the passageways 7 are located at the lowermost part of the recessed regions or valleys between raised projections on the contoured upper surface 8. If required the mould may be comprises of a porous or foraminous material to facilitate evacuation of the air between the membrane and the upper surface 8.
The air is then evacuated and as the membrane comes into contact with the surface of the mould 1 it stretches in some regions to accommodate the contours of the mould.
The membrane is then manipulated if required by pushing with fingertips or a similar soft instrument to align the printed indicia with respective topographical features in the mould cavity. To assist in initial location of the membrane 2 the membrane and/or the upper surface 8 of the mould may include markings or alignment indicia which are brought into registration prior to evacuation of the air. Due to the resilience of the membrane substrate the membrane may be stretched or contracted as required to accurately position the indicia relative to corresponding topographical features on the mould surface.
When the printed membrane is accurately positioned, the mould is then closed by upper mould half 11 and reactive polyurethane components are injected into the mould via injection port 12.
The components are allowed to react to fill the mould cavity and after curing the moulded article is removed. The membrane print substrate may then be peeled from the surface of the moulded article leaving the print chemically bonded to the contoured surface of the article.
The resultant article is a three dimensional topographical contour map having accurately marked thereon indicia representing roads, contour lines, rivers, vegetation, etc.
Apart from the obvious advantages of accurate marking of topographical features, three dimensional topographical contour maps made in accordance with the invention are far more durable than prior art three dimensional maps of this kind. Prior art maps were generally made from vacuum formed high impact polystyrene sheet which is relatively brittle and thus easily broken. Possibly the major disadvantage of such prior art maps is that the printed surface is not resistant to scratching and thus after a period of use in the field the printed indicia became difficult to read thus necessitating replacement of the maps. Other advantages possible with the present invention and absent from prior art maps of this kind are the ability to form composite maps by abutting the upstanding edges of the moulded articles and due to their resilient nature, marking pins or the like may be readily inserted into the surface and relocated as required without significant damage to the printed surface. Maps according to the invention may be cleaned by simply washing with water and soap or detergent and they may be exposed to weathering over extended periods without significant deterioration.
Printed articles made in accordance with the above embodiment are highly durable due to the inherent flexibility and abrasion resistance of polyurethane compounds.
The articles can be made according to the RIM process with a wide variety of physical properties as required from rigid polyurethane foams through to flexible foams.
By utilizing a transparent membrane substrate the membrane may be left in contact with the printed surface to provide a protective covering if required.
Although the preferred embodiment has been described with reference to a resilient rubber latex membrane it is believed that the inherent elastomeric qualities of polyurethane may permit the manufacture of a polyurethane print substrate membrane which could be permanently bonded to the finished article.
It will be apparent that the process according to the invention may be applicable to a wide variety of articles moulded by the RIM process. For example the process may be utilized for in-mould printing of contoured articles such as decorative plaques, mannikins for display of clothing, integrally moulded furniture items, self-skinning vehicle upholstery covers or seating, display signs, toys and the like. Other applications of the invention may include in-mould application of labels or other indicia to a part only of the surface of the article.
The surface of the membrane substrate may be textured by say a casting process to impart a textured finish to the moulded article. Such textures may be evenly appllied to all surfaces of the finished article e.g. a reptile skin texture, or applied selectively to certain regions i.e. a trade mark or manufacturer's label. It will be clear to a skilled addressee that the ability to apply textured finishes to RIM moulded articles will substantially decrease the cost of mould manufacture.
In a modification of the invention the process may be employed to achieve "in-mould" printing of say labels on injection moulded or blow moulded articles. In this modification a strip of resilient printed substrate is positioned between mould halves. As the mould halves are clamped shut, the resilient substrate is clamped firmly between the abutting mould faces and when material is injected or blown into the mould cavity the substrate is forced against the surface of the mould whereupon the printed indicia is transferred to the moulded article. If required the membrane may be located on the inner surface of the mould by evacuating perforated passageways in the mould wall. The membrane would act as a barrier to material entering the air evacuation passageways. Obviously the nature of the elastomeric substrate and the chemical composition of the printing medium are chosen to suit the operating conditions and the chemical nature of the material being moulded to effect a suitable transfer of the printed indicia.
In yet another modification of the invention a printed transparent substrate may be applied to an outer surface of an article with a bonding medium therebetween. Initially the bonding medium may act as a lubricant to enable accurate positioning of the printed indicia relative to the article to which it is being applied. When the printed indicia is accurately positioned the bonding medium may be cured by heat, electromagnetic radiation or the like to effect transfer of the print.
In yet a further modification of the invention the membrane, bearing a transferable indicia, may be applied to the surface of a pre-moulded article. The membrane may be retained in a desired position against the surface of the article by an externally applied positive air pressure or by internally evacuating the mouled article. Print transfer may then occur by any suitable process such as by heating or the like whereby the transferable indicia supported on the membrane chemically bonds to the surface of the moulded article.
It will be readily apparent to a skilled addressee that many modifications and variations will be possible with the invention without departing from the spirit and scope thereof. | A printing method for moulded plastics articles comprises printing of selected indicia onto an elastomeric film (2), locating the printed film (2) in a mould cavity (3) with the printed surface facing inwardly and the evacuating the air space between the film (2) and the mould surface (8). With the printed film (2) located firmly against the mould cavity (3), the film (2) is manipulated to bring the printed indicia into register with surface features of the mould (8). Plastics material is injected into the mould cavity (4) and during solidification, the printed indicia is transferred from the film (2) to the surface of the moulded article with the printed indicia in accurate register with surface features of the moulded article. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 09/171,653, filed Mar. 17, 1999, which was a U.S. national phase of PCT/DK97/00190, filed Apr. 24, 1997.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a safety child barrier of the type which includes a gate mounted in a frame, the barrier being fastenable in an opening using clamping devices which can be clamped against the sides of the opening.
Child safety gates are used as temporary barriers across doorways, stairways, windows, and similar openings to prevent small children and animals from passing therethrough.
There are known child safety barriers which include a frame with a central gate and there are also known barriers where the gate is located at one side thereof.
The purpose of this invention is to provide gates of enhanced reliability. The barrier has a special hinge construction which prevents buckling at the hinge, and the barrier has also a special closing mechanism having an extra protection against unintended opening. Finally, the barrier includes an indicator device to indicate the clamping in the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention shall be explained further below with reference to the enclosed drawings.
FIG. 1 is a perspective view of a child safety barrier constructed in accordance with a preferred embodiment of the present invention, the barrier including a frame and a gate hinged thereto,
FIG. 2 is a view of one end of the base member of the frame and showing a closing mechanism for clamping against a side of an opening in which the barrier is positioned,
FIG. 3 is a perspective view of a locking hinge between the upper end of the gate and vertical post of the frame,
FIG. 4 is a view of a hinge between the lower end of the gate and the base member of the frame,
FIGS. 5, 5 a , 6 , 7 and 11 depict the closing mechanism at the free end of the upper rod of the gate,
FIGS. 8-9 depict a blocking device located at the free end of the upper rod of the gate,
FIG. 10 shows a pressure indicator unit in the upper rod of the frame, and
FIG. 12 shows a cross section of a free end of a threaded bar of the closing mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The child safety barrier includes a frame having a base member 2 and an upright post member 4 , a short upper rod member 6 extending to one side at the upper end of the post member. Vertical rods 8 extend between the upper rod member and the base member. On the other side of the post a gate 10 is hinged.
For fastening of the barrier in the opening there is in each corner of the plane of the barrier, i.e., in both ends of the base member 2 and the free end of the upper member 6 a threaded rod 12 with a friction block. The threaded rods can be pulled in and out and fixed by means of a counter nut 14 so that their length can be adjusted to the size of the actual opening.
The gate includes a closing mechanism 48 which also has a corresponding threaded bar with a friction block which can be pulled in and out and fixed with a counter nut, and which by means of the closing mechanism can be clamped against the opening.
At the top of the gate 10 is hinged to the post 4 by means of a specially designed hinge 16 . As shown in FIG. 3, a substantially tube-shaped upper hinge part 18 of plastic with a hole 20 for a pivot pin 22 is mounted over the upper rod 54 of the gate. At this location the hinge part is solid. On the lower part of the hinge part there is a slot 24 . The other hinge part 26 is attached to the post 4 , on to which an angle 28 is welded. The hinge part has a pocket, by means of which this can be slipped in over the perpendicularly projecting flap of the angle on the post. On the upper part of the hinge part there is a fin 30 projecting upwards, which fits loosely up into the slot 24 on the other hinge part. There is also a through-going hole 32 for the pivot pin 22 . The hole is carried through the angle so that the hinge part is fixed by means of the pivot pin 22 . On the lower side of the hinge part the hole is continued in a tube section and at the back there is a contact surface facing the post or more precisely the angle. Furthermore, there is a reinforcing rib. The pivot pin 22 is attached by tight fitting or by screwing it into the upper part 18 of the hinge, and in the closed position of the gate the pivot is still hidden in the hinge, i.e., the pivot does not project beneath the hinge.
As shown in FIG. 4, at its bottom the gate is hinged to the base member by means of a pivot pin 34 situated through a hole in the bottom rod 36 of the gate further down through a hole in the top side of the base member 2 of the frame. The end of the pivot pin 34 is bent to the side so that it functions as a stop for pulling up the gate. The pivot pin is inserted by manipulating it through the hole in the bottom rod of the gate and further down into the bottom rod of the frame. The pivot pin 34 can be welded to the gate by the head.
To open the barrier the gate is lifted by means of which the upper part of the hinge 16 is lifted clear of the fin 30 on the lower part 26 . When the gate is swung open the upper part 18 will ride on the fin 30 . The vertical lift of the gate is as mentioned limited by the pivot pin 34 in the bottom hinging of the gate. In the closed position of the gate the hinge is fixed against sideways deflection as the fin 30 here is situated in the slot 24 on the under side of the upper part 18 of the hinge. Furthermore, the forces appearing in the upper member of the gate will be transmitted directly to the vertical post 4 , as the rear edge of the upper hinge part is at the top shaped as an planar contact plane 40 for contact against the pillar whereas the edge at the slot region is shaped as rounded sliding surfaces 42 situated within the contact plane. In the open position the contact plane 40 is lifted above the pillar 4 and by swinging up the gate, the sliding surface 42 will slide upon the pillar. Altogether, the upper part of the barrier will in closed position stand as a nearly rigid through-going connection including the upper rod the gate, the upper part of the pillar and the upper rod of the frame.
In closed position the front corner at the bottom of the gate is secured against deflection by means of an U-shaped element 44 gripping around the top side of the base member 2 . By lifting the gate for its opening, the element 44 clears the base member. The element 44 is positioned on the rounding where the lower rod of the gate curves into the front rod 46 , by means of which the wedge-shaped space next to the base member is blocked so that children cannot get their toes or fingers caught in the gate.
As seen in FIGS. 5-7, the gate includes a closing mechanism 48 , which also has a threaded bar 50 with a friction block 50 a . The threaded bar is situated in a through-going hole in a sliding element 52 and extends with its end into the upper rod 54 . In the element 52 a nut 56 is cast so that the threaded bar can be screwed in and out to fit the actual size of an opening. At the front the element 52 has a sideways projecting cross wall 58 , to which in each side a recess with a camface 60 is contigous. A handle 62 (see FIG. 5 a ) comprises two parallel sidewalls 64 , which on the rear section is connected with a curved member 66 fitting the upper rod 54 of the gate. At the front the sidewalls have a side plate with a projection 70 cooperating with the camface 60 in the recess on the element 52 . When the handle 62 is closed, i.e., in horizontal position, the threaded bar and thereby the friction block are in their projecting locked position. When opening the gate the handle is turned, thus causing the pins 70 in cooperation with the camface to pull back the threaded bar with the friction block out of contact with the opening, in which the barrier is placed. The gate can then be lifted and opened as described previously. When closing the gate the handle is pushed downwards, thus causing the front edge of the sides 64 to press against the cross wall 58 of the element by means of which this is pushed forward to clamp the friction block against the opening. On the edge of the element there is a projection 72 cooperating with a slot 74 in the side plates. In a closed position the projections are positioned in the slot. By lifting the handle to open the gate, the projections 72 will counteract this. Only with an extra firm grip on the handle it will be possible to swing it upwards as the sidewalls thereby are forced from each other and slide on top of the projections. On the other hand, the projections will cooperate in causing the handle to shut with a “snap effect” and to remain in the closed position.
As an additional securing feature preventing opening of the gate, the handle is blocked by means of a spring-loaded blocking plastic block 78 (see FIGS. 8 and 9 ). This block is firmly fixed between a projecting end of the upper rod 54 of the gate and a parallel flat iron 80 welded to the front rod 46 , which is a pipe, and the neighbour rod 82 of the gate. The rear edge of the block is undercut and grips around the rod 82 . At the front the block is fixed by means of a pin 84 which projects downwardly into the pipe 46 . The axis of rotation of the handle is embedded in a cross hole 86 in the block. The blocking knob 76 is designed as an entity with the plastic block and placed against the side plates 68 or designed as shown in FIG. 11 as a spring-loaded 100 loose knob 102 embedded in a recess 104 in the plastic block 78 , and which grips into a hole in the side plate 68 of the handle. The handle is thus blocked in the closed position. In order to open the gate two independent movements are thus necessary, i.e., pushing into the blocking knob 76 as well as lifting the handle. Beyond this, the entire gate has to be lifted. The gate is hereby effectively secured against unintended opening, and at the same time it is still easy to open for an adult person. Besides being an integrated part of the plastic block, the blocking knob can of course also be shaped as a separate spring-loaded knob embedded in the plastic piece.
Due to the yielding of the opening where the barrier is placed, e.g., yielding banisters, it can be difficult to decide how hard the gate has to be clamped. For this purpose the upper rod of the frame is shaped as an indicator unit. As shown in FIG. 10, a spring 87 is positioned in rod 6 for affecting a pipe section 88 in which the threaded bar 12 with the friction block 12 a is situated. On the pipe there are two indication marks 90 , 92 , the first showing the sufficient clamping of the frame itself, the second showing sufficient clamping of the closing mechanism of the gate.
In order to improve the securing of the rubber or plastic coating (covering) 94 of the friction block on the supporting plate 96 , this can be equipped with one or several holes 98 , mainly three evenly distributed over the plate, and where the coating penetrates into the holes, cf. FIG. 12 . The coating is thus effectively secured against stripping off by sideways forces on the gate. This applies by loosely fixed coating as well as vulcanized coating. | A child safety barrier for positioning across an opening includes a frame and a gate which is hinged to the frame and can be swung from a closed position where the gate lies in the plane of the frame to an open position out of the plane, a corner of the barrier including a spring-biased threaded rod with friction block which can be pressure fit against a side of the opening and includes markers for indicating the degree of pressure fit within the opening. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to craft hoops, and, more particularly, to a craft hoop clamp.
[0003] 2. Description of the Related Art
[0004] Craft hoops also known as embroidery hoops or knitting rings, generally include concentric inner and outer hoops. The inner hoop has a fixed diameter and the outer hoop has an adjustable diameter. Material, such as fabric, is placed upon the inner hoop while the outer hoop is placed over the fabric and around the inner hoop. The outer hoop is then adjusted such that the outer hoop fits snugly against the material and the inner hoop so as to hold the material between the inner and outer hoops. Craft work is then undertaken on the fabric held between the inner hoop and outer hoop.
[0005] Embroidery has been traditionally used to decorate clothing and household furnishings including such items as table linens, towels, bedding and decorative items. Most embroidered products are assembled from several individual pieces of fabric. Prior to assembling each piece of fabric, upon which an embroidered design or logo is to be placed, the fabric is inserted into an embroidery hoop and secured to the hoop. The hoop is then embroidered either by hand or with an embroidery machine.
[0006] Embroidery hoops have been known and used in both home and in factories for many years. Spring type embroidery hoops are used for hand and machine operations. Spring type hoops tension the outer hoop entirely by the resilience of the spring. More commonly, embroidery hoops such as circular or oval shaped units have an outer threaded fastener that traverses the split in the outer hoop for tightening the outer hoop against the inner hoop.
[0007] The problem with conventional embroidery hoops or craft hoops has been the difficulties with the tensioning mechanism. The screw type tensioning mechanism generally requires the use of two hands to position and tighten the threaded bolt with a wing nut. The disadvantage of the spring type embroidery hoop is that the tension is related only to the spring force and the force from the spring decreases as the hoop is drawn together.
[0008] What is needed in the art is a tensioning device which is easily operable with one hand and adjustable to provide variable tension on a craft hoop.
SUMMARY OF THE INVENTION
[0009] The present invention provides an adjustable tensioning device for a craft hoop assembly.
[0010] The invention comprises, in one form thereof, a craft hoop assembly including a split hoop having a first end and a second end and a clamping mechanism connected to the first end, the clamping mechanism having a first pivot point and a second pivot point, the first pivot point associated with the first end, the second pivot point associated with the second end.
[0011] An advantage of the present invention is that a split craft hoop can be secured around an inner hoop using only one hand.
[0012] Another advantage is that a conventional outer hoop can be retrofitted with a kit of the present invention.
[0013] Yet another advantage is that the craft hoop clamping method provides an adjustable over-center type mechanism for tensioning the outer hoop.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0015] [0015]FIG. 1 is a perspective view of an embodiment of a craft hoop clamping apparatus of the present invention;
[0016] [0016]FIG. 2 is an exploded perspective view of the craft hoop clamping apparatus shown in FIG. 1;
[0017] [0017]FIG. 3 is a partially sectionalized view of the craft hoop clamping apparatus shown in FIGS. 1 and 2;
[0018] [0018]FIG. 4 is a partially sectionalized view of the craft hoop clamping apparatus shown in FIGS. 1 - 3 ;
[0019] [0019]FIG. 5 is a partially sectionalized side view of the craft hoop clamping apparatus of FIGS. 1 - 4 ; and
[0020] [0020]FIG. 6 is a view of another embodiment of the clamping apparatus in the form of a kit for a conventional craft hoop assembly.
[0021] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to the drawings, and, more particularly to FIGS. 1 and 2, there is shown an embodiment of a craft hoop clamping apparatus 10 of the present invention, which generally includes split hoop 12 and over-center clamp mechanism 14 .
[0023] Split hoop 12 is a generally circular hoop that has a split 16 along the circumference thereof. Split hoop 12 may be made from a variety of materials such as wood, plastic or carbon fiber. The inner surface, although shown as smooth in FIG. 1, may include ridges to better grip a fabric. Although split hoop 12 is shown as a circular hoop other shapes such as elliptical or quasi-rectangular may be incorporated as a part of craft hoop clamping apparatus 10 . Alternatively, more than one over-center clamp mechanism 14 may be applied along the circumference of a split hoop.
[0024] Over-center clamp mechanism 14 includes retaining block 18 , recessed block 20 , over-center tensioner 22 , tensioning rod retainer 24 , tensioning rod 26 , rod spring 28 and expansion spring 30 . Retaining block 18 is attached to one end of split hoop 12 and retaining block 18 is aligned with recessed block 20 . Retaining block 18 includes an opening 36 through which tensioning rod 26 is disposed. Tensioning rod 26 is retained by retaining block 18 to thereby provide tension on split hoop 12 . Recessed block 20 is attached to another end of split hoop 12 and is aligned with retaining block 18 . Recessed block 20 includes elongated opening 38 through which tensioning rod 26 is disposed and recess 40 which serves as a bearing surface for tensioner 22 .
[0025] Over-center tensioner 22 includes bearing surface 42 , handle 44 and slot 48 . Axis A and axis B denote two pivot points about which portions of over-center tensioner 22 rotate. Bearing surface 42 contacts recess 40 to provide pressure against recessed block 20 , thereby placing tension on split hoop 12 . Bearing surface 42 is part of a circumference of a substantially circular portion of over-center tensioner 22 that rotates about axis A. Handle 44 provides a mechanical advantage to over-center tensioner 22 and allows an operator to thereby put pressure on tensioning rod 26 . In a preferred embodiment of the present invention handle 44 exceeds two inches in length. Threaded portion 46 of tensioning rod retainer 24 engages tensioning rod 26 in an adjustable manner. Tensioning rod retainer 24 is retained in over-center tensioner 22 by the connection with tensioning rod 26 . Tensioning rod retainer 24 rotates about axis B such that when handle 44 is moved to a position adjacent to recessed block 20 , that tensioning rod 26 crosses axis A, thereby biasing handle 44 to remain adjacent to recessed block 20 . Such an arrangement is known as an over-center condition. Slot 48 allows space for tensioning rod 26 to travel when over-center tensioner 22 is rotated. Tensioning rod retainer 24 is positioned off center relative to bearing surface 42 to provide a camming type action as over-center tensioner 22 is rotated. Over-center tensioner 22 can be in the form of a cam clamp or a toggle clamp.
[0026] Tensioning rod 26 includes a retaining end 32 in the form of a ball 32 on one end thereof and a threaded end 34 on an opposite end thereof. Retaining end 32 has a retaining surface for rod spring 28 to rest against. The portion of retaining end 32 directed away from tensioning rod 26 may include a tab that protrudes or a slot therein, thereby accommodating a rotational adjustment of tensioning rod 26 . Rod spring 28 is positioned on tensioning rod 26 prior to tensioning rod 26 being inserted into retaining block 18 . Rod spring 28 comes into contact with a surface of retaining block 18 and provides tension within over-center clamp mechanism 14 while it is unlatched. Tensioning rod 26 traverses the inner diameter of expansion spring 30 , which is positioned between retaining block 18 and recessed block 20 . Expansion spring 30 is positioned to cause split hoop 12 to part along split 16 when tension on tensioning rod 26 is released. Tensioning rod 26 also is disposed through elongated opening 38 of recessed block 20 . Threaded end 34 adjustably engages threaded portion 46 of tensioning rod retainer 24 . Tensioning rod 26 , also known as tensioning member 26 , may be embodied as a flexible member such as a cable with retaining end 32 connected thereto.
[0027] Alternatively, over-center clamp mechanism 14 may be configured to provide a compressive force on an inner split hoop. The compressive force is exerted against an outer hoop.
[0028] Now, additionally referring to FIGS. 3 - 5 , there is shown the operation of craft hoop clamping apparatus 10 . In FIG. 3 there is shown inner hoop 50 surrounded with craft hoop assembly 10 in an unlatched position. As handle 44 of over-center tensioner 22 is rotated in direction R tensioning rod 26 is drawn against retaining block 18 causing split 16 to narrow. As over-center tensioner 22 is rotated tensioning rod 26 , as shown in FIG. 4, is angularly offset. As shown in FIG. 5 over-center tensioner 22 is in a latched position, with tensioning rod 26 being slightly above centerline A thereby keeping over-center tensioner 22 in the latched position. Split 16 is substantially reduced in width when over-center clamp mechanism 14 is in the latched position, thereby causing split hoop 12 to be drawn tight against inner hoop 50 .
[0029] Craft hoop assembly 10 is operated by placing over-center tensioner 22 in an unlatched position. Fabric is placed over inner hoop 50 and arranged as required by the user who may be an embroiderer or quilter. Outer hoop 12 is then placed over the fabric locating outer hoop 12 substantially concentric with inner hoop 50 . Over-center tensioner 22 is then rotated, thereby placing tension on tensioning rod 26 , causing split hoop 12 to close split 16 and securing tension against the fabric placed over inner hoop 50 . Over-center tensioner 22 is rotated until it is in a latched position to securely hold the fabric placed over inner hoop 50 . Retaining rod 26 is adjustable within tensioning rod retainer 24 thereby providing an adjustable amount of tension on split hoop 12 .
[0030] Now, additionally referring to FIG. 6, there is illustrated another embodiment of the present invention in the form of a craft hoop clamping kit 110 shown with a conventional craft hoop. A conventional craft hoop includes outer split hoop 112 , protrusion 122 , protrusion 124 and a bolt with wing nut 126 . Protrusions 122 and 124 are respectively connected to an end of split hoop 112 and bolt/wing nut 126 is disposed therethrough, the combination thereby accommodating the tensioning of split hoop 112 . Craft hoop clamping kit 110 , which is substantially similar to over-center clamp mechanism 14 , is installed by first removing winged bolt 126 from protrusions 122 and 124 . Retaining rod 26 is unscrewed from tensioning rod retainer 24 . Tensioning rod 26 is then routed through protrusions 122 and 124 where bolt 126 had been and tensioning rod 26 is then re-threaded into tensioning rod retainer 24 . Retaining block 118 and recessed block 120 are shortened versions of retaining block 18 and recessed block 20 of the previous embodiment. The surface of recess block 120 that bears upon protrusion 124 is slidingly engaged to allow tensioner 22 to operate in a camming type manner.
[0031] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A craft hoop assembly including a split hoop having a first end and a second end and a clamping mechanism connected to the first end, the clamping mechanism having a first pivot point and a second pivot point, the first pivot point associated with the first end, the second pivot point associated with the second end. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of International Application No. PCT/US2011/036814, filed May 17, 2011, which claims priority to U.S. Provisional Application Ser. No. 61/345,831, filed May 18, 2010. The disclosures of the aforementioned applications are incorporated herein by reference in their entireties for all purposes.
FIELD OF THE INVENTION
The present invention relates to a method for purifying a pyrrolocarbazole derivative (compound of formula (I) or compound (I)) using an acid complex thereof. The present invention also relates to a crystalline form of an acid complex of formula (Ia).
BACKGROUND OF THE INVENTION
A specific fused pyrrolocarbazole compound known as 11-isobutyl-2-methyl-8-(2-pyrimidinylamino)-2,5,6,11,12,13-hexahydro-4Hindazolo[5,4-a]pyrrolo[3,4-c]carbazol-4-one is a potent, orally-active TIE-2/VEGF-R 40 inhibitor having anti-tumor and anti-angiogenic activity and is represented by the following formula (I):
This compound is herein-referred to as compound (I). U.S. Pat. No. 7,169,802 describes compound I and utility thereof. It notably discloses a method of preparation of this compound according to scheme 1:
However, the inventors have shown that compound (I) is resulting with poor yields of about 38% and low purity according to such procedure. In particular, it has been shown that the compound of formula (I) thus resulting, contained a high level of the by-product of formula (IV).
This by-product resulting from the elimination of two hydrogen atoms in the indazolyl moiety of the compound of formula (I) and hence from the aromatization of the ring system, turned out to be particularly difficult to separate from compound of formula (I).
Thus, several purification steps, notably by column chromatography, were required to obtain compound (I) with a pharmaceutically acceptable purity, notably of more than 95%, thus even further lowering the yields.
Therefore, there is a need for an improved process for the manufacture of compound (I) from compound (II) that overcomes the drawbacks of the prior art and, in particular, allows to obtain satisfactory yields and purity.
SUMMARY OF THE INVENTION
The present invention in one aspect provides an acid complex of compound (I). Unexpectedly, the inventors have thus discovered that the crystallization of such a complex allows removing most of the impurities, notably those that are difficult to eliminate by conventional techniques, such as chromatography, and hence to obtain a high purity level.
Thus, the acid complex of the compound (I) according to the invention makes the subsequent purification of compound (I) easier and thus provides a process that is workable on a industrial scale. In particular, it reduces the need of large volumes of solvent generally required for purification by chromatography.
Another object of the present invention is to provide a method for preparing the acid complex of the compound of formula (I) from the compound (II). Advantageously, it has been demonstrated that the use of a base during the nucleophilic substitution step allows increasing the yields of the acid complex and thus of the compound of formula (I), as well as to reduce the resulting impurities. In particular, it has been shown that the presence of a base does not increase the degradation of compound (II).
Another object of the present invention is to provide the use of such an acid complex for purifying compound (I) and notably to reach a purity of more than 95%.
Another object of the present invention is to provide a method for the purification of compound (I), notably comprising the treatment of the acid complex with a decolorizing agent in order to remove the by-product compound of formula (IV).
Still another object of the present invention is to provide a crystalline form of the acid complex of formula (Ia).
These and other objects, features and advantages of the invention will be disclosed in the following detailed description.
DESCRIPTION OF THE FIGURES
FIG. 1 represents an X-ray powder diffractogram of form A 0 of compound (I).
FIG. 2 represents the X-ray powder diffractogram of the acetic acid complex of compound of formula (I).
FIG. 3 represents the 1 H NMR spectrum of the acetic acid complex of the compound of formula (I).
DETAILED DESCRIPTION OF THE INVENTION
Thus, in one aspect, the invention provides an acid complex of a compound of formula (I):
said acid complex having the following formula (Ia):
wherein R represents C 1 -C 8 alkyl.
The carboxylic acid RCOOH can be selected in the list consisting of acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid or octanoic acid.
In a particular aspect, RCOOH represents acetic acid. It should be understood that the acetic acid complex of compound I can be referred to as an acid complex of formula (Ia) wherein R represents C 1 alkyl.
In a further aspect, R represents C 2 -C 8 alkyl.
In an additional aspect, the invention provides a method for the preparation of the acid complex of formula (Ia), as herein-defined, comprising:
i) contacting a compound of formula (II) with a compound of formula (III) in the presence of a base in a solvent;
wherein Hal represents Br, Cl, or I;
ii) contacting the resulting compound of formula (I) with an acid of formula RCOOH; and optionally iii) recovering the resulting acid complex of formula (Ia).
Step i)
In another aspect, the base is an amine, notably a secondary or tertiary amine. In still another aspect, the amine is a trialkylamine. In yet another aspect, the amine is of formula R 1 R 2 R 3 N, wherein R 1 represents C 1 -C 6 alkyl and R 2 , R 3 are independently selected in the list consisting of H and C 1 -C 6 alkyl. Preferably, the amine is a trialkylamine wherein R 1 , R 2 and R 3 independently represent C 1 -C 6 alkyl, notably diisopropylamine or triethylamine; triethylamine being particularly preferred.
Advantageously, it has been shown that the presence of the base enhances the reaction kinetic, while enabling both to increase the yield and the purity of the reaction, notably by reducing the amounts in by-products, in particular those related to the degradation of the compounds of formula (II). Further, it has been observed that the base does not increase the amount of by-product of formula (IV).
In yet a further aspect, the molar ratio of the base relatively to the compound of formula (II) ranges from 1 to 2, and is notably of about 1.5 equivalent.
In still a further aspect, the molar ratio of the compound of formula (III) relative to the compound of formula (II) ranges from 1 to 2, and is notably of about 1.5 equivalent.
There is no particular restriction on the nature of the solvent to be employed, provided that it has no adverse effect on the reaction or on the reagents involved. Examples of suitable solvents include polar solvents, notably alcohols, in particular alcohols having a boiling point above 100° C., such as n-butanol.
The reaction can take place over a wide range of temperatures, and the precise reaction temperature is not critical to the invention. In general, the reaction mixture is heated to reflux, notably at a temperature ranging from 100 to 120° C.
The time required for the reaction may also vary widely, depending on many factors, notably the reaction temperature and the nature of the reagents. While the progress of the reaction can be monitored by HPLC, a period of about 18 to 22 hours is generally sufficient.
Step ii)
According to step ii), the compound of formula (I) is contacted with a carboxylic acid of formula RCOOH. In a preferred embodiment, the carboxylic acid is added to the reaction mixture resulting at the end of step i).
Preferably, the volume of RCOOH that is added to the reaction mixture ranges from 1 to 20 volumes, notably from 5 to 15 volumes, relative to the compound of formula (II) or (I).
The temperature of addition of the acid RCOOH to the reaction mixture is not critical. It can be chosen notably between the boiling point and the melting point of the acid RCOOH, and in particular in the range of 60 to 120° C. Preferably, the reaction mixture of step i) is cooled to about 75° C., before the acid RCOOH is added.
The reaction mixture is then generally heated to a temperature ranging from 60° C. to 80° C., notably at 75° C., over a period of about 10 to 30 minutes.
Step iii)
In an additional aspect, the acid complex of formula (Ia) is recovered from the reaction mixture.
In a particular embodiment, step iii) comprises:
a) crystallizing the resulting acid complex of formula (Ia); and b) recovering the crystallized complex of formula (Ia).
The complex of formula (Ia) form can be crystallized from the reaction mixture by conventional methods, including notably cooling or chilling, crystal seeding, evaporation of a portion of the solution, or precipitation by adding an anti-solvent such as methyl tert-butyl ether (MTBE).
A preferred embodiment comprises cooling the reaction mixture to about 20° C. In particular, the reaction mixture can be cooled rapidly by standard cooling methods, typically with a temperature cooling rate in the range of −0.1° C./min to −10° C./min.
The crystallized complex of formula (Ia) can be isolated by any conventional methods including filtration and centrifugation. The recovered crystals of the acid complex may then be washed with a solvent, for instance with methyl tert-butyl ether (MTBE).
In an additional aspect, the invention provides a crystalline form of an acid complex of formula (Ia):
wherein R represents C 1 alkyl, characterized by an X-ray powder diffractogram comprising one or more of the following peaks: 5.19±0.2 degrees 2-Theta; 6.17±0.2 degrees 2-Theta; 6.44±0.2 degrees 2-Theta; 14.36±0.2 degrees 2-Theta; and 26.09±0.2 degrees 2-Theta, when measured using Cu-Kα radiation. In one aspect, the X-ray powder diffractogram comprises a peak at 6.44±0.2 degrees 2-Theta and one or more of the following peaks: 5.19±0.2 degrees 2-Theta; 6.17±0.2 degrees 2-Theta; 14.36±0.2 degrees 2-Theta; and 26.09±0.2 degrees 2-Theta, when measured using Cu-Kα radiation. In another aspect, the X-ray powder diffractogram comprises peaks at 6.44±0.2 degrees 2-Theta and 6.17±0.2 degrees 2-Theta and one or more of the following peaks: 5.19±0.2 degrees 2-Theta; 14.36±0.2 degrees 2-Theta; and 26.09±0.2 degrees 2-Theta, when measured using Cu-Kα radiation. In a further aspect, the X-ray powder diffractogram comprises peaks at 6.44±0.2 degrees 2-Theta; 6.17±0.2 degrees 2-Theta; and 26.09±0.2 degrees 2-Theta and one or more of the following peaks: 5.19±0.2 degrees 2-Theta and 14.36±0.2 degrees 2-Theta, when measured using Cu-Kα radiation. In a still further aspect, the X-ray powder diffractogram comprises peaks at 5.19±0.2 degrees 2-Theta; 6.17±0.2 degrees 2-Theta; 6.44±0.2 degrees 2-Theta; 14.36±0.2 degrees 2-Theta; and 26.09±0.2 degrees 2-Theta, and one or more of the following peaks: 10.51±0.2 degrees 2-Theta; 15.84±0.2 degrees 2-Theta; 18.33±0.2 degrees 2-Theta; 20.69±0.2 degrees 2-Theta; and 23.71±0.2 degrees 2-Theta, when measured using Cu-Kα radiation. In a yet further aspect, the crystalline acetic acid complex of formula (Ia) has an X-ray powder diffractogram substantially as depicted in FIG. 2 .
In a preferred embodiment, the crystalline form of an acid complex of formula (Ia) where R represents C 1 alkyl has a purity of at least about 92%. In a more preferred embodiment, the crystalline form of an acid complex of formula (Ia) where R represents C 1 alkyl has a purity of at least about 97%. In a still more preferred embodiment, the crystalline form of an acid complex of formula (Ia) where R represents C 1 alkyl has a purity of at least about 99.5%.
Advantageously, it has been shown that the crystallization of the complex of formula (Ia) allows to eliminate most of the impurities resulting from the preparation steps of compound of formula (I). Thus, after crystallization, the resulting complex is generally recovered in a purity ranging from 92 to 99.5% or more. In particular, removing the majority of the impurities generally allows a purity ranging from 92 to 97%. The remaining impurities are mainly by-product of formula (IV) that tends to crystallize together with the acid complex of formula (I). Further removing compound of formula (IV) hence allows a purity equal or greater than 99.5%.
In an additional aspect, the invention provides an acid complex of formula (Ia) obtainable according to the method herein-disclosed.
In still an additional aspect, the invention provides the use of an acid complex of formula (Ia) for purifying or in a method for purifying the corresponding compound of formula (I) or a pharmaceutically acceptable salt thereof.
In a preferred embodiment, the purified compound of formula (I) has a purity of more than 98%, preferably of more than 99%.
In an additional aspect, the invention provides a method for the purification of the compound of formula (I) as herein-defined, comprising:
i) converting the acid complex of formula (Ia) as herein-defined into the corresponding compound of formula (I); ii) contacting the resulting compound of formula (I) with a decolorizing agent; and optionally iii) recovering the purified compound of formula (I).
In yet another aspect, the step of converting the acid complex of formula (Ia) into the compound of formula (I) is carried out by drying the complex at a temperature comprised in the range of from 70° C. to 90° C., notably at a temperature of about 80° C.
Alternatively, the step of converting the acid complex of formula (Ia) into the compound of formula (I) can be carried out by dissolving in a solvent the complex of formula (Ia), notably in a solvent suitable for crystallizing the compound of formula (I), for example under the polymorphic form A 0 . Polymorphic form A 0 of compound (I) has been disclosed in international patent application n° PCT/US2009/065099, the content of which is herein-incorporated by reference.
FIG. 1 represents an X-ray powder diffractogram of form A 0 of compound (I). It presents representative peaks according to Table 1.
TABLE 1
Angle
d-spacing
Intensity
Peak No.
[°2 Theta]
[Angstrom]
[%]
1
6.70
13.19
100
2
7.00
12.62
67
3
8.19
10.78
63
4
10.97
8.06
16
5
13.22
6.69
15
6
13.39
6.61
51
7
13.69
6.46
84
8
14.45
6.12
8
9
15.35
5.77
6
10
15.98
5.54
11
11
16.24
5.45
59
12
16.80
5.27
16
13
17.19
5.15
5
14
17.44
5.08
41
15
18.79
4.72
11
16
19.34
4.59
35
17
19.94
4.45
5
18
20.57
4.31
15
19
21.04
4.22
13
20
21.19
4.19
7
21
21.51
4.13
13
22
21.72
4.09
13
23
22.72
3.91
8
24
23.30
3.82
10
25
23.72
3.75
5
26
24.26
3.67
91
27
27.05
3.29
23
28
28.64
3.11
7
29
31.26
2.86
6
Suitable solvents for crystallizing the compound of formula (I) under the polymorphic form A 0 may notably be selected in the list consisting of 1-butanol; 1-pentanol; 1-propanol; 2-butanol; 2-butanone; 2-pentanone; 3-pentanone; acetone; acetonitrile; butyronitrile; chlorobenzene; cyclohexane; dichloromethane; di-isopropyl-amine; dimethyl-sulfoxide; EGDE; ethanol; ethyl acetate; ethylene glycol; heptane; iPrOH; isopropyl acetate; methanol; methyl acetate; methyl ethyl ketone; methyl isopropyl ketone; methyl tert-butyl ether; n-butyl-acetate; pentanol; propanitrile; pyridine; sec-butanol; tetrahydrofuran; tetrahydropyrane; toluene; triethylamine; water; xylene; and mixtures thereof, including 6:4 N-methylpyrrolidone; water; 1:1 N-methylpyrrolidone:water; 9:1 1-2 dichloromethane; N-methylpyrrolidone; 7:3 1-2 dichloromethane; isopropyl acetate.
The dissolution of the complex can be performed at a temperature in the range of 60° C. and 80° C., notably of about 70° C., under stirring.
The progress of the reaction of conversion of the acid complex into the compound of formula (I) can be monitored by RX diffraction. Thus, the conversion reaction can be performed over a period sufficient to convert the whole acid complex of formula (Ia) into the compound of formula (I).
In a preferred embodiment, the resulting compound of formula (I) is recovered from the reaction mixture prior the step of treatment with the decolorizing agent, notably by crystallizing the compound of formula (I) and isolating the crystals.
Crystallization can be performed by any conventional methods, including notably cooling or chilling, crystal seeding, evaporation of a portion of the solution, or precipitation by adding an anti-solvent.
A preferred embodiment comprises cooling the reaction mixture to about 10° C., notably rapidly by standard cooling methods, typically with a cooling rate temperature in the range of −0.1 to −10° C./min.
The crystallized compound of formula (I) can be isolated by any conventional methods including filtration and centrifugation. The recovered crystals of the compound of formula (I) may then be washed with a solvent, for instance with isopropyl acetate. The isolated product may then be dried under vacuum.
In a particular aspect, the step of contacting the compound of formula (I) with a decolorizing agent is carried out in a solvent selected in the list consisting of dichloromethane, methanol, ethanol or any solvent capable to solubilise compound (I) or any binary or ternary mixture thereof.
In yet a further aspect, the decolorizing agent is an activated charcoal, notably a steam or chemically activated charcoal. Examples of suitable activated charcoals are those provided under the trade names LSM™, L3S™, 3S™, DARCO G60™ for steam activated charcoals and CPL™, ENO PC™, CAP SUPER™ for chemically activated charcoals; typically from Ceca or Norit manufacturers. Preferred charcoal is ENO PC™ charcoal.
Advantageously, it has been shown that the decolorizing agent allows substantially removing by adsorption, any residual by-products which can be present in the reaction mixture together with the compound of formula (I) (or with the acid complex of formula (Ia) respectively), in particular the by-product of formula (IV).
The purified compound of formula (I) may then be recovered by filtering the reaction mixture, and evaporating the solvent under vacuum.
The recovered compound of formula (I) may then be optionally recrystallized, notably under polymorphic form A 0 . In a certain aspect, the compound of formula (I) can be dissolved in isopropylacetate and then cooled to a temperature of about 10° C. to 20° C. until complete formation of polymorphic form A 0 .
The crystals of the purified compound of formula (I) may then be recovered by any conventional methods, notably by centrifugation, and washed with a solvent such as isopropylacetate.
In another aspect, the invention provides a method for the purification of the compound of formula (I) as herein-defined, said method comprising the steps of:
i) contacting the acid complex of formula (Ia) as herein-defined with a decolorizing agent in a solvent; ii) converting the resulting acid complex of formula (Ia), into the corresponding compound of formula (I); and optionally iii) recovering the purified compound of formula (I).
The steps of treatment with a decolorizing agent (step i) and of conversion of the acid complex of formula (Ia) into the compound of formula (I) (step ii) can be performed according to the same procedures than those herein-disclosed.
In a still further aspect, the resulting purified compound of formula (I) is further reacted with an acid so as to obtain an acid addition salt, preferably a monoacid addition salt.
In another aspect, the acid is the paratoluenesulfonic acid (PTSA).
The following terms and expressions used herein-have the indicated meanings.
As used herein, the term “about” refers to a range of values from ±10% of a specified value. For example, the phrase “about 50 mg” includes ±10% of 50, or from 45 to 55 mg.
The term “complex”, as used herein, refers to the non covalently bounded association of two molecules of the acid RCOOH with one molecule of the compound of formula (I).
As used herein, the term “alkyl” refers to a straight-chain, or branched alkyl group having 1 to 8 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, isoamyl, neopentyl, 1-ethylpropyl, 3-methylpentyl, 2,2-dimethylbutyl, 2,3-dimethylbutyl, hexyl, octyl, etc. Lower alkyl groups, which are preferred, are alkyl groups as defined above which contain 1 to 4 carbons. A designation such as “C1-C4 alkyl” refers to an alkyl radical containing from 1 to 4 carbon atoms.
The term “solvent,” as used herein, means a substance, typically a liquid, that is capable of completely or partially dissolving another substance, typically a solid, and which is nonreactive towards the starting reagents, the intermediates or the products, at the reaction temperature considered, it being possible for the latter to vary from the solidification point of the solvent to the boiling point of the solvent.
The term “anti-solvent,” as used herein, means a solvent in which a compound is substantially insoluble.
As used herein, the term “decolorizing agent” refers to a porous or finely divided carbon, notably activated, with a large surface area, that can adsorb coloured impurities from the liquid reaction mixture, notably aromatic impurities.
As used herein, the term “volume” or “V”, when referring to a ratio, means a (liter/kilogramme) (L/kg) ratio.
EXAMPLES
Other features of the invention will become apparent in the course of the following descriptions of exemplary embodiments. These examples are given for illustration of the invention and are not intended to be limiting thereof.
Material and Methods
Compound (II) is supplied by Cephalon (typical purity>92% LCAP); it can be prepared according to the preparation of example I-29 of WO-2005/063763.
Triethylamine was purchased from SAFC (typical purity>99%). 2-BromoPyrimidine was purchased from Acros (typical purity>98%). Solvents were purchased from SDS Carlo Erba (typical purity: PPS grade)
HPLC
A reversed-phase HPLC method was developed and qualified for determining the identity, the assay and purity of compound of formula (I) drug substance. The analysis is performed on an XTerra MS C18 column (150×4.6 mm, 5 μm packing) using a 55-85% organic gradient over 27 minutes, and measuring the absorbance at 270 nm.
Analysis Parameters
Column: Xterra MS C18, 150×4.6 mm, 5μ
Column temperature: 30° C.
Injection volume: 10 μL
Detection: UV, 270 nm
Flow rate: 1.0 mL/min
Run time: 27 minutes
Mobile phase A: 10 mM aqueous ammonium acetate
Mobile phase B: 10 mM ammonium acetate in 50:50 acetonitrile/methanol
Gradient:
Time (min) % A % B 0.0 45 55 7.0 40 60 11.0 40 60 23.0 15 85 23.1 45 55 27.0 45 55
X-Ray Powder Diffraction (XRPD)
The X-ray powder diffraction (XRPD) pattern for the acetic acid complex of compound of formula (I) was resulting using a Rigaku Miniflex II diffractometer using Cu Kα radiation.
FIG. 2 represents the X-ray powder diffractogram of the acetic acid complex of compound of formula (I). It presents representative XRPD peaks according to Table 2.
TABLE 2 XRPD peaks of the crystallized acetic acid complex of formula (Ia) Angle d-spacing Intensity I Peak n o (2-Theta) (Å) (%) 1 5.19 17.01 17.5 2 6.17 14.31 53.3 3 6.44 13.71 100.0 4 8.38 10.54 1.7 5 10.51 8.41 13.0 6 11.03 8.01 8.6 7 12.34 7.17 8.1 8 13.19 6.71 2.0 9 14.36 6.16 29.7 10 15.20 5.82 1.2 11 15.84 5.59 14.9 12 16.19 5.47 8.5 13 17.19 5.15 4.8 14 17.51 5.06 4.1 15 18.33 4.84 16.7 16 19.51 4.55 2.8 17 20.69 4.29 17.2 18 21.51 4.13 5.9 19 22.39 3.97 5.1 20 22.98 3.87 8.5 21 23.71 3.75 13.1 22 24.89 3.57 5.4 23 26.09 3.41 33.8 24 26.73 3.33 4.0 25 27.84 3.21 1.5 26 28.28 3.15 1.5 27 28.55 3.12 1.6 28 29.52 3.02 2.9 29 29.85 2.99 5.5 30 30.87 2.89 2.5 31 32.06 2.79 1.6 32 33.02 2.71 2.5 33 33.80 2.65 1.0 34 34.13 2.62 1.0 35 34.84 2.57 2.7 36 35.21 2.55 2.1 37 36.38 2.47 3.4 38 36.81 2.44 5.9
Nuclear Magnetic Resonance (NMR)
The NMR spectra were acquired on a Bruker Avance AV-400 spectrometer operating at 400 MHz for 1 H spectra and 100 MHz for 13 C spectra using CDCl 3 as the solvent.
FIG. 3 represents the 1 H NMR spectrum of the acetic acid complex of the compound of formula (I). It presents representative peaks according to table 3. Peaks at 0.88 (corresponding to the compound (I)) and at 2.13 (corresponding to acetic acid) confirm the presence of two molecules of acetic acid for one molecule of compound of formula (I).
TABLE 3
1H δ/TMS
13C δ/TMS
Position
Group
(ppm)
(ppm)
1
C
—
174.03
2
NH
8.58
—
3
CH2
4.86
44.64
4
C
—
117.68
5
C
—
116.78
6
C
—
118.29
7
CH
8.22
112.73
8
C
—
149.76
9
NH
—
—
10
C
—
160.25
11
CH
8.41
157.93
12
CH
6.72
111.75
13
CH
7.59
119.81
14
CH
7.41
110.51
15
C
—
138.87
16
CH2
4.35
53.21
17
CH
2.22
30.31
18
CH3
0.88
20.21
19
C
—
139.77
20
C
—
122.07
21
CH2
2.98
21.00
22
CH2
3.48
25.68
23
C
—
141.77
24
CH3
3.95
38.77
25
CH
8.82
132.41
26
C
—
127.47
27
C
—
114.38
28
C
—
138.87
29
CH3
2.13
21.56
30
C═O
—
175.87
31
OH
—
—
Example 1
Preparation of the Acetic Acid Complex of Formula (Ia)
A reactor was charged at about 20° C. with the compound of formula (II) (12.99 kg; 1 eq) and butanol-1 (130 L; 10 V). The mixture was stirred (80 rpm) at 20° C. for 5 minutes. Triethylamine (6.82 L; 1.5 eq.) and 2-bromo pyrimidine (7.79 kg; 1.5 eq) were added at 20° C. Then the reaction mixture stirred at 100 rpm was heated to reflux (TM=117° C.) at least 20 h (checking that the reaction was complete by HPLC, if it is necessary, continue the reflux). After cooling the mixture to 60° C., acetic acid (195 L) was added. The mixture was heated to 75° C. (disappearance of solid particles) and stirred for 15 minutes. Then, the mixture was cooled to 20° C. (−0.3° C./min) and was stirred for 2 hours. The precipitated solids were isolated by centrifugation and washed with Methyl tert-Butyl Ether (MTBE). The product was dried under vacuum at 40° C. to yield 17.9 kg of the acetic acid complex of formula (Ia) with a yield of 92% and a purity of 96.5%.
Example 2
Converting the Acetic Acid Complex into the Compound of Formula (I) Via a Polymorphic Transformation
A reactor was charged at about 20° C. with the acetic acid complex of example 1 (9.02 kg; 1 eq) and isopropyl acetate (390 L; 40V). The mixture was stirred (80 rpm) at 20° C. for 15 minutes. After heating to 70° C., the mixture was stirred at 80 rpm until complete formation of polymorphic form A 0 (checking that the reaction was complete by RX). Then the reaction mixture was cooled to 10° C. and was stirred for at least 2 hours. The precipitated solids were isolated by centrifugation and washed with isopropyl acetate. The product was dried under vacuum at 40° C. to yield 6.11 kg of crude compound (I) as form A 0 (yield=85.6%)
Example 3
Charcoal Treatment and Polymorphic Transformation into Purified Compound of Formula (I)
A reactor was charged at about 20° C. with crude the compound of formula (I) form A 0 (4.040 kg; 1 eq, dichloromethane (222 L; 40V) and ethanol (56 L; 10 V). The mixture was stirred yield (80 rpm) at 20° C. for 15 minutes in order to obtain a solution perfectly clear. The mixture was purified with 50% w/w activated charcoal lens (2×1 kg; 49.5% w/w). Then the liquors were filtered through a 0.3 μm Cuno filter cartridge to remove insoluble particles (activated charcoal). The solvents were evaporated until dryness under vacuum. Isopropyl acetate (265 L; 58 V) was added to the mixture and 50 L of azeotropic mixture was evaporated under vacuum. After cooling the mixture to 20° C., the mixture was stirred at 80 rpm until complete formation of polymorphic form A 0 (checking that the reaction was complete by RX/DSC, if it is necessary, heat to 70° C.). Then the reaction mixture was cooled to 10° C. The precipitated solids were isolated by centrifugation and washed with isopropyl acetate. The product was dried under vacuum at 40° C. to yield the compound (I) under form A 0 (3.280 kg; yield=81.19%; purity=99.2%).
Example 4
Preparation of the Acid Addition Salt of the Compound of Formula (I) with PTSA (Monotosylate)
A reactor was charged at about 20° C. with the compound of formula (I) form A 0 (6.075 kg; 1 eq) and dichloromethane (92 L; 15 V). The mixture was stirred (80 rpm) at 20° C. for 15 minutes. After cooling the mixture to 10° C., paratoluene sulfonic acid (PTSA—2.417 kg; 1 eq) was added portion wise. The mixture was stirred at 80 rpm at 10° C. for 1 hour. Then, MTBE (122 L; 15 V) was added portion wise via a feed vessel. The mixture was heated to 45° C. at least 1 h (checking that the reaction was complete by RX/DSC, if it is necessary, continue the contact). After cooling the mixture to 10° C., the precipitated solids were isolated by filtration and washed with MTBE. The product was dried under vacuum at 40° C. to yield the addition salt of compound of formula (I) with PTSA (8.045 kg; yield=97.3%; purity=99.1%).
Example 5
Preparation of the Compound of Formula (I) Free Base of Formula (I) from Compound of Formula (II)
A reactor was charged at about 20° C. with the compound of formula (II) (1 eq) and butanol-1 (10 V). The mixture was stirred (80 rpm) at 20° C. for 5 minutes. Triethylamine (1.4 eq.) and 2-bromo pyrimidine (1.4 eq) were added at 20° C. Then the reaction mixture stirred at 100 rpm was heated to reflux (TM=117° C.) at least 20 h (checking that the reaction was complete by HPLC, if it is necessary, continue the reflux). After cooling the mixture to 75° C., acetic acid (5V) was added. The mixture was stirred at 75° C. until the disappearance of solid particles. Then, the mixture was cooled to 20° C. (—0.3° C./min). The precipitated solids (wet compound (I)/acetic acid complex of formula (Ia)) were isolated by centrifugation and washed with methyl-tert-butyl-ether (MTBE). The product was dried under vacuum at 80° C. to yield compound (I) as its free base of formula (I). | The present invention relates a method for purifying a fused pyrrolocarbazole compound known as 11-isobutyl-2-methyl-8-(2-pyrimidinylamino)-2,5,6,11,12,13-hexahydro-4Hindazolo[5,4-a]pyrrolo[3,4-c]carbazol-4-one using an acid complex thereof. The present invention also relates to a crystalline form of the acid complex. | 2 |
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to washing machines, and more particularly to vertical axis washing machines with steam features.
BACKGROUND OF THE INVENTION
[0002] Washing machines typically include a cabinet which receives a stationary tub for containing wash and rinse water. A wash basket is rotatably mounted within the wash tub, and an agitating element is rotatably positioned within the wash basket. A drive assembly and a brake assembly can be positioned with respect to the wash tub and configured to rotate and control the agitation of the wash basket to cleanse the wash load loaded into the wash basket. Upon completion of a wash cycle, a pump assembly can be used to rinse and drain the soiled water to a draining system.
[0003] Certain horizontal axis washers are equipped with the capability to produce steam inside the cabinet. However, there are currently no vertical axis machines that satisfactorily provide this capability.
[0004] Thus, a need exists for a top load washing machine that provides steam features to enhance garments. Mechanisms for circulating steam throughout a top load washing machine would be particularly useful.
BRIEF DESCRIPTION OF THE INVENTION
[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0006] One exemplary embodiment of the present disclosure is directed to a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater, a water level sensor, and a fan. The water level sensor controls the volume of water that enters the tub such that the fan is not submerged in such volume of water and the heater generates steam from such volume of water. During generation of steam, the fan rotates and circulates air inside the tub so that the steam is distributed throughout the tub. Spinning of the basket, the impeller or both can constitute the fan as described, although the fan could be separate from the basket or impeller.
[0007] Another exemplary embodiment is directed to a method for operating a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater and a water level sensor. The method includes adding water to the tub until a predetermined volume of water has been added. The volume of water is only sufficient for generating steam. The water level sensor is utilized to determine when the predetermined volume of water has been added. The method further includes initiating the heater after the predetermined volume of water has been added to generate steam from the predetermined volume of water.
[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0010] FIG. 1 is a perspective cutaway view of an exemplary top load washing machine according to an exemplary embodiment of the present disclosure;
[0011] FIG. 2 is a front schematic view of the washing machine shown in FIG. 1 ; and
[0012] FIG. 3 is a schematic block diagram of a control system for the washing machine shown in FIG. 1 and FIG. 2 in accordance with certain aspects of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, 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 scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0014] In general, the present disclosure is directed to a top load washing machine that includes the ability to produce steam. When a predetermined level of water is added to the washer as determined by one or more water level sensor(s), a heater is utilized to produce steam within the washer. As is known to one of ordinary skill in the art, since heat rises such steam would typically concentrate in the upper portion of the washing machine. Importantly, the present disclosure permits distribution of steam throughout the washing machine. Steam can be utilized to remove wrinkles in garments as well as for more efficient cleaning of garments.
[0015] FIG. 1 is a perspective view partially broken away of an exemplary top load (vertical axis) washing machine 50 including a cabinet 52 having a top portion 54 . A backsplash 56 extends from top portion 54 , and a control panel 58 including a plurality of input selectors 60 is coupled to backsplash 56 . Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment, a display 61 indicates selected features, a countdown timer, and other items of interest to machine users. A lid 62 is mounted to top portion 54 and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to wash tube 64 located within cabinet 52 , and a closed position (shown in FIG. 1 ) forming an enclosure over wash tub 64 .
[0016] Tub 64 includes a bottom wall 66 and a sidewall 68 , and a basket 70 is rotatably mounted within wash tub 64 . The top portion of tub 64 generally defines a tub opening (not shown). A pump assembly 72 is located beneath tub 64 and basket 70 for gravity assisted flow when draining tub 64 . Pump assembly 72 includes a pump 74 and a motor 76 . A pump inlet hose 80 extends from a wash tub outlet 82 in tub bottom wall 66 to a pump inlet 84 , and a pump outlet hose 86 extends from a pump outlet 88 to an appliance washing machine drain outlet 90 and ultimately to a building plumbing system discharge line (not shown) in flow communication with drain outlet 90 .
[0017] FIG. 2 is a front elevational schematic view of washing machine 50 including wash basket 70 movably disposed and rotatably mounted in wash tub 64 in a spaced apart relationship from tub side wall 68 and tub bottom. A wash load such as garment 75 is disposed within basket 70 . The top portion of tub 64 generally defines a tub opening 73 . Basket 70 includes a plurality of perforations therein to facilitate fluid communication between an interior of basket 70 and wash tub 64 .
[0018] A hot liquid valve 102 and a cold liquid valve 104 deliver fluid, such as water, to basket 70 and wash tub 64 through a respective hot liquid hose 106 and a cold liquid hose 108 . Liquid valves 102 , 104 and liquid hoses 106 , 108 together form a liquid supply connection for washing machine 50 and, when connected to a building plumbing system (not shown), provide a fresh water supply for use in washing machine 50 . Liquid valves 102 , 104 and liquid hoses 106 , 108 are connected to a basket inlet tube 110 , and fluid is dispersed from inlet tube 110 through a known nozzle assembly 112 having a number of openings therein to direct washing liquid into basket 70 at a given trajectory and velocity. A known dispenser 153 (shown in FIG. 3 , not shown in FIG. 2 ), may also be provided to produce a wash solution by mixing fresh water with a known detergent or other composition for cleansing of articles in basket 70 .
[0019] In an alternative embodiment, a known spray fill conduit 114 (shown in phantom in FIG. 2 ) may be employed in lieu of nozzle assembly 112 . Along the length of the spray fill conduit 114 are a plurality of openings arranged in a predetermined pattern to direct incoming streams of water in a downward tangential manner towards articles in basket 70 . The openings in spray fill conduit 114 are located a predetermined distance apart from one another to produce an overlapping coverage of liquid streams into basket 70 . Articles in basket 70 may therefore be uniformly wetted even when basket 70 is maintained in a stationary position.
[0020] A known agitation element 116 , such as an impeller is disposed in basket 70 to impart an oscillatory motion to garments and liquid in basket 70 while leaving sufficient room to hang a garment as will be described in more detail herein. In addition, in embodiments where the agitation element 116 is an impeller, the impeller can be utilized to circulate steam as will be described in greater detail herein. As illustrated in FIG. 2 , agitation element 116 is oriented to rotate about a vertical axis 118 .
[0021] Basket 70 and agitator 116 are driven by motor 120 through a transmission and clutch system 122 . A transmission belt 124 is coupled to respective pulleys of a motor output shaft 126 and a transmission input shaft 128 . The drive system may also be of the direct type where no belt is necessary and the motor is directly inline with the drive shaft. Thus, as motor output shaft 126 is rotated, transmission input shaft 128 is also rotated. Clutch system 122 facilitates driving engagement of basket 70 and agitation element 116 for rotatable movement within wash tub 64 , and clutch system 122 facilitates relative rotation of basket 70 and agitation element 116 for selected portions of wash cycles. Motor 120 , the transmission and clutch system 122 and belt 124 collectively are referred herein as a machine drive system.
[0022] Washing machine 50 also includes a brake assembly (not shown) selectively applied or released for respectively maintaining basket 70 in a stationary position within tub 64 or for allowing basket 70 to spin within tub 64 . Pump assembly 72 is selectively activated, in the example embodiment, to remove liquid from basket 70 and tub 64 through drain outlet 90 and a drain valve 130 during appropriate points in washing cycles as machine 50 is used.
[0023] Operation of machine 50 is controlled by a controller 138 which is operatively coupled to the user interface input located on washing machine backsplash 56 (shown in FIG. 1 ) for user manipulation to select washing machine cycles and features such as wash cycles and steam cycles as will be described in more detail herein. In response to user manipulation of the user interface input, controller 138 operates the various components of machine 50 to execute selected machine cycles and features.
[0024] Referring to FIG. 3 , controller 138 can, for example, be a microcomputer 140 coupled to a user interface input 141 . An operator may enter instructions or select desired washing machine cycles and features via user interface input 141 , such as through input selectors 60 (shown in FIG. 1 ) and a display or indicator 61 coupled to microcomputer 140 displays appropriate messages and/or indicators, such as a timer, and other known items of interest to washing machine users. A memory 142 is also coupled to microcomputer 140 and stores instructions, calibration constants, and other information as required to satisfactorily complete a selected wash cycle. Memory 142 may, for example, be a random access memory (RAM). In alternative embodiments, other forms of memory could be used in conjunction with RAM memory, including but not limited to flash memory (FLASH), programmable read only memory (PROM), and electronically erasable programmable read only memory (EEPROM).
[0025] Power to controller 138 can be provided by a power supply 146 configured to be coupled to a power line L. Analog to digital and digital to analog converters (not shown) are coupled to controller 138 to implement controller inputs and executable instructions to generate controller output to washing machine components such as those described above in relation to FIGS. 1 and 2 . More specifically, controller 138 is operatively coupled to water level sensor 202 and heater 204 (as further described herein) in addition to machine drive system 148 (e.g., motor 120 , clutch system 122 , and agitation element 116 shown in FIG. 2 ), a brake assembly 151 associated with basket 70 (shown in FIG. 2 ), machine water valves 152 (e.g., valves 102 , 104 and diverter valve 184 shown in FIG. 2 ) and machine drain system 154 (e.g., drain pump assembly 72 and/or drain valve 130 shown in FIG. 2 ) according to known methods.
[0026] In an illustrative embodiment, laundry items are loaded into basket 70 , and washing operation is initiated through operator manipulation of control input selectors 60 (shown in FIG. 1 ). Tub 64 is filled with water and mixed with detergent to form a wash fluid, and basket 70 is agitated with agitation element 116 for cleansing of laundry items in basket 70 . That is, agitation element is moved back and forth in an oscillatory back and forth motion. In the illustrated embodiment, agitation element 116 is rotated clockwise a specified amount about the vertical axis of the machine, and then rotated counterclockwise by a specified amount. The clockwise/counterclockwise reciprocating motion is sometimes referred to as a stroke, and the agitation phase of the wash cycle constitutes a number of strokes in sequence. Acceleration and deceleration of agitation element 116 during the strokes imparts mechanical energy to articles in basket 70 for cleansing action. The strokes may be obtained in different embodiments with a reversing motor, a reversible clutch, or other known reciprocating mechanism.
[0027] After the agitation phase of the wash cycle is completed, tub 64 is drained with pump assembly 72 . Laundry items are then rinsed and portions of the cycle repeated, including the agitation phase, depending on the particulars of the wash cycle selected by a user.
[0028] In accordance with the present disclosure, the washing machine can also advantageously permit one or more steam cycles and/or fabric enhancing cycles. Heretofore, top load (vertical axis) washing machines have not included steam features. In accordance with the present disclosure, steam features are described in connection with top load washing machines. In this manner, consumers of top load washing machines can enjoy the deep clean benefits afforded by steam. The washing machines described herein can also permit reduction and/or elimination of wrinkles from garments.
[0029] Referring to FIG. 2 , sump 200 is in fluid communication with tub 64 . Sump 200 can be of any suitable size and/or shape to permit a volume of water to accumulate for the production of steam as will be described herein. In this manner, water can flow into tub 64 as previously described herein and fill sump 200 .
[0030] Water level sensor 202 can be positioned in or adjacent to sump 200 and can control the volume of water to ensure that only a predetermined volume of water enters sump 200 . Water level sensor 202 can be any suitable water level sensor as would be known to one of ordinary skill in the art. Water level sensor 202 can be in communication with controller 138 such that water level sensor 202 can cause the flow of water into tub 64 to stop when the volume of water in sump 200 reaches a predetermined sufficient volume.
[0031] In this regard, sump 200 can include heater 204 . Heater 204 is immersed by the volume of water in sump 200 and once the volume of water reaches a predetermined level, heater 204 can be activated by controller 138 and increase in temperature to boil the water and generate steam. Steam can rise and fill tub 64 . Any suitable heater as would be known to one of ordinary skill in the art can be utilized for such purpose. Heater 204 can be deactivated by controller 138 when water level sensor 202 indicates that some portion or substantially all of the volume of water in sump 200 has been released into the tub 64 as steam.
[0032] Steam can be circulated throughout tub 64 with fan 206 . Fan 206 can be located in any suitable location within tub 64 so as to enable effective circulation of steam. In an particular embodiment, fan 206 can be represented by spinning the basket and or the impeller to circulate air. In this regard, due to the buoyant nature of steam and the physical configuration of a vertical axis washing machine, steam typically concentrates toward the top portion 208 of tub 64 . Fan 206 can ensure that steam is distributed more evenly throughout the tub 64 . The speed, direction, and duration of operation of fan 206 can be activated by controller 138 as steam is being generated by heater 204 . Fan 206 can also be activated after steam generation is complete. Fan 206 can operate for predetermined intervals of time based on the steam cycle selected by a user. In certain embodiments, agitation 116 can also be utilized as fan 206 .
[0033] A reservoir (not shown) is located within washing machine 50 and can receive fragrant material added by a user. Fragrant material can include liquid fragrant material or solid fragrant capsules. Reservoir can be in communication with controller 138 and release the fragrant material to be delivered into the volume of water to generate a fragrant steam. For instance, reservoir can be opened based upon a fabric enhancing cycle being selected by a user. Although illustrated within washing machine 50 , reservoir can also be located outside of washing machine in communication with tub 64 .
[0034] A pumping mechanism (not shown) can be utilized to direct fragrant material into sump 200 . Fragrant material can dissolve or mix with water in sump 200 so that a fragrant steam can be distributed throughout the tub 64 . The fragrant material can take any form including a liquid additive such as detergent or fabric softener, a powered additive or any other scented fluid, gel, tablet, capsule or powder.
[0035] Referring again to FIG. 2 , washing machine 50 can also include a removable garment hanger 214 . Removable garment hanger 214 can hang within tub 64 . In this regard, tub 64 can define any suitable feature such as tabs, hooks, fasteners, or the like to mount removable garment hanger 214 within tub 64 . In certain embodiments of the present disclosure, one or more sensors or transducers 156 can detect the presence and/or absence of removable garment hanger 214 and communicate the same to controller 138 . In this manner, when removable garment hanger 214 is positioned within tub 64 , the user interface 141 can optionally only permit access to steam cycle functions of the washing machine 50 . However, it should be appreciated that the steam features described herein can also be used in combination with washing cycles as would be appreciated by one of ordinary skill in the art and the presence of garment hanger 214 within tub 64 does not necessarily require disabling of wash cycle features.
[0036] For instance, a regular wash load of garments can be loaded into the basket of a top load washing machine. The steam features described herein can be utilized at any suitable time during the regular wash cycle(s). In certain embodiments, the steam features can be activated to add fragrant steam in the tub after an initial wash. Spinning the basket and/or impeller and/or use of a fan can be utilized to distribute the steam throughout the washing machine. Similarly, in certain embodiments, one or more garments can be hung in basket and a steam cycle can be utilized to freshen such garments without the necessity for a full wash cycle. Alternatively, or in conjunction with such freshening, wrinkles can also be reduced or eliminated from the use of a steam cycle without the necessity of a full wash cycle.
[0037] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | One exemplary embodiment of the present disclosure is directed to a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater, a water level sensor, and a fan. The water level sensor controls the volume of water that enters the tub such that the fan is not submerged in such volume of water and the heater generates steam from such volume of water. The fan rotates and circulates air inside the tub so that the steam is distributed throughout the tub. | 3 |
FIELD OF THE INVENTION
This invention relates to liquid oligomers containing unsaturation which can be crosslinked using ultraviolet light without adding costly photoinitiators. Films made from the crosslinked oligomers of the inventions are used as protective or decorative coatings on various substrates. The oligomers can be added to other resins used in adhesives or composites.
BACKGROUND OF THE INVENTION
Acrylate, methacrylate and other unsaturated monomers are widely used in coatings, adhesives, sealants, and elastomers, and may be crosslinked by ultraviolet light radiation or peroxide initiated free radical cure. These are typically low molecular weight multifunctional compounds which may be volatile or readily absorbed through skin and can cause adverse health effects. Functionalized polymers may overcome some of these drawbacks; generally, polymers are nonvolatile compounds, not readily absorbed through skin. However, multistep syntheses may be required, low functionality may be detrimental to reactivity and final properties, and catalyst or initiator may be required to effect crosslinking.
The Michael addition of acetoacetate donor compounds to multiacrylate receptor compounds to make crosslinked polymers has been described in the literature. For example, Mozner and Rheinberger reported the Michael addition of acetoacetates having a β-dicarbonyl group to triacrylates and tetracrylates. Macromolecular Rapid Communications 16, 135-138 (1995). The products formed were crosslinked gels. In one of the reactions, Mozner added one mole of trimethylol propane triacrylate (TMPTA) having 3 functional groups to one mole of polyethylene glycol (600 molecular weight) diacetoacetate (PEG600-DAA) having two functional groups. (Each "acetoacetate functional group" reacts twice, thus each mole of diacetoacetate has four reactive equivalents.) ##STR1## Mole Ratio of TMPTA: PEG 600 DAA=1:1 Ratio of acrylate: acetoacetate functional groups=3:2
Ratio of reactive equivalents=3:4
BROAD DESCRIPTION OF THE INVENTION
This invention is the discovery that certain soluble liquid uncrosslinked oligomers, made by one step Michael addition of acetoacetates to multiacrylates, can be further crosslinked using ultraviolet light without using costly photoinitiators.
We have discovered that when precise proportions of multiacrylate acceptor compounds to acetoacetate donor compounds are combined using a basic catalyst, liquid oligomeric compositions are the product. If proportions below the claimed ranges are used, crosslinked gels or solid products are made which are not useful for the purposes of this invention because only un-gelled, uncrosslinked liquid oligomers will further crosslink without adding photoinitiators. In addition, the liquid oligomer compositions of this invention, since they are liquids, can readily be applied to various substrates using conventional coating techniques such as roll or spray prior to ultraviolet light cure.
BRIEF DESCRIPTION OF THE DRAWING
The graph illustrates that ratios below the three curves were unuseable gelled materials outside the scope of the invention. Ratios on or above the curves are the liquid oligomers of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Among the multiacrylates used to make the oligomers of this invention are diacrylates, triacrylates, and tetraacrylates. ##STR2##
The Michael addition reaction is catalyzed by a strong base; diazabicycloundecene (DBU) is sufficiently strong and readily soluble in the monomer mixtures. Other cyclic amidines, for example diazabicyclo-nonene (DBN) and guanidines are also suitable for catalyzing this polymerization.
Michael addition of a methacrylate functional β-dicarbonyl compound, 2-acetoacetoxyethyl methacrylate (AAEM), to diacrylate monomer yields liquid linear polyesters with reactive pendant methacrylate groups, which can be crosslinked in a subsequent curing reaction. As the acrylate and acetoacetate are mutually reactive and the methacrylate is inert under the conditions of the Michael addition, a highly functionalized (one methacrylate per repeat unit), liquid uncrosslinked polymer can be obtained in a one-step, ambient temperature, solventless reaction. The high selectivity of the Michael reaction permits the use of monomers such as styrene and methyl methacrylate as inert solvents to give low-viscosity systems that are easily incorporated into a variety of laminating resins.
In the following Examples all parts are by weight unless otherwise indicated. In addition, all references mentioned herein are specifically incorporated by reference.
A series of experiments defined the proportions of multi-acrylate to β-dicarbonyl acetoacetate which separate the liquid oligomer products of this invention from the gel or solid products of the prior art.
Synthetic Procedure
An example of resin synthesis is as follows. Trimethylolpropane triacrylate (TMPTA) 59.2 g and diazabicycloundecene (DBU) 0.4 g were weighed into a 500 ml 3-neck round bottom flask equipped with a mechanical stirrer and addition funnel. Ethyl acetoacetate (EM) 13.0 g was weighed into the addition funnel. The TMPTA and DBU were mixed for 5 minutes prior to addition of the EAA. EAA was then added dropwise to the stirred TMPTA/DBU mixture over a 15 minute period. The solution warmed to 54 degrees Centigrade after addition of EAA was complete. After the exotherm subsided in 100 minutes a viscous yellow liquid was obtained which did not gel upon standing.
The same general procedure can be employed for a variety of combinations of acrylate and acetoacetate functional reactants, provided the equivalent ratio of acrylate:acetoacetate is sufficient to yield liquid, uncrosslinked products. For particularly exothermic or large scale reactions, controlled, gradual addition of acetoacetate and/or cooling of the reaction may be required to prevent premature, thermally initiated crosslinking of acrylate functional groups.
TABLE 1______________________________________Acetoacetate/Acrylate Mixturesaceto- mole equiv weight reactionacetate acrylate f ratio ratio ratio ratio product______________________________________A ethyl hexane- 2:2 1:1 2:2 36.5:63.5 viscous diol liquid*B ethyl penta- 2:4 1:10 1:20 3.6:96.4 viscous ery- liquid* thritolC butane- hexane- 4:2 1:1 2:1 53.3:46.7 crosslinked diol diol gel**D penta- penta- 8:4 1:10 1:5 11.8:88.2 crosslinked ery- ery- gel** thritol thritol______________________________________ *soluble in methyl ethyl ketone (MEK) at room temperature. **insoluble in refluxing methyl ethyl ketone.
A and B made useful oligomers of the inventor. C and D made crosslinked gels which are outside the invention.
TABLE 2______________________________________Reactions of diacrylate acceptor with acetoacetate-functional donors. Func- tion- Equiv- Reac- ality Mole alent Weight tionAcceptor Donor ratio ratio ratio ratio product______________________________________TRPGDA MeOAcAc 2:2 1:1 1:1 72.1:27.9 solTRPGDA EtOAcAc 2:2 1:1 1:1 69.8:30.2 solTRPGDA aceto- 2:2 1:1 1:1 62.9:37.1 sol acetanilideTRPGDA butanediol 2:4 7.7:1 3.9:1 90:10 sol di-OAcAcTRPGDA 2:4 4.9:1 24:1 85:15 gelTRPGDA 2:4 3.44:1 1.7:1 80:20 gelTRPGDA cyclohexane 2:4 19.8:1 9.9:1 95:05 sol dimethanol di-TRPGDA di-OAcAc 2:4 13.8:1 6.9:1 93:7 solTRPGDA 2:4 94:1 4.7:1 90:10 gelTRPGDA 2:4 5.9:1 2.95:1 85:15 gelTRPGDA 2:4 4.2:1 2.1:1 80:20 gelTRPGDA neopentyl 2:4 8.2:1 4.1:1 90:10 sol glycolTRPGDA di-OAcAc 2:4 5.1:1 2.6:1 85:15 solTRPGDA 2:4 3.6:1 1.8:1 80:20 gelTRPGDA TONE 2:6 16.6:1 5.5:1 90:10 sol 0301 tri- OAcAcTRPGDA 2:6 10.4:1 3.5:1 85:15 gelTRPGDA 2:6 7.4:1 2.5:1 80:20 gelTRPGDA glycerin 2:6 10.3:1 3.4:1 90:10 sol tri-OAcAcTRPGDA 2:6 6.5:1 2.2:1 85:15 gelTRPGDA 2:6 4.6:1 1.5:1 80:20 gelTRPGDA pentaery- 2:8 14.2:1 3.5:1 90:10 sol thritol tetra-OAcAcTRPGDA 2:8 8.9:1 2.2:1 85:15 gelTRPGDA 2:8 6.3:1 1.6:1 80:20 gel______________________________________
Review of Table 2 shows that certain diacrylate-acetoacetate equivalent ratios make sol or liquid oligomers of the invention.
TABLE 3______________________________________Reactions of triacrylate acceptor with acetoacetate-functional donors. Func- tion- Equiv- Reac- ality Mole alent Weight tionAcceptor Donor ratio ratio ratio ratio product______________________________________TMPTA EtOAcAc 3:2 2:1 3:1 82:18 solTMPTA EtOAcAc 3:2 3:2 2.25:1 77.4:22.6 solTMPTA EtOAcAc 3:2 4:3 2:1 75.2:24.8 gelTMPTA butanediol 3:4 7.8:1 5.9:1 90:10 sol di-OAcAcTMPTA 3:4 4.9:1 3.7:1 85:15 gelTMPTA 3:4 3.5:1 2.6:1 80:20 gelTMPTA cyclohexane 3:4 9.5:1 7.1:1 90:10 sol dimethanol di-TMPTA di-OAcAc 3:4 6.0:1 4.5:1 85:15 gelTMPTA 3:4 4.2:1 3.2:1 80:20 gelTMPTA neopentyl 3:4 8.3:1 6.2:1 90:10 sol glycolTMPTA di-OAcAc 3:4 5.2:1 3.9:1 85:15 gelTMPTA 3:4 3.7:1 2.8:1 80:20 gelTMPTA TONE 3:6 16.8:1 8.4:1 90:10 sol 0301 tri- OAcAcTMPTA 3:6 10.6:1 5.3:1 85:15 gelTMPTA glycerin 3:6 14.3:1 7.2:1 92.5:7.5 sol tri-OAcAcTMPTA 3:6 10.5:1 52:1 90:10 gelTMPTA pentaery- 3:8 30.3:1 11.4:1 95:5 sol thritol tetra- OAcAcTMPTA 3:8 19.7:1 7.4:1 92.5:7.5 solTMPTA 3:8 14.4:1 5.4:1 90:10 gel______________________________________
Review of Table 3 shows that certain triacrylate:acetoacetate ratios make sol or liquid oligomers of the invention.
TABLE 4______________________________________Reactions of tetraacrylate acceptor with acetoacetate-functional donors. Func- tion- Equiv- Reac- ality Mole alent Weight tionAcceptor Donor ratio ratio ratio ratio product______________________________________PETA EtOAcAc 4:2 3.3:1 6.6:1 90:10 solPETA EtOAcAc 4:2 2:1 4.0:1 84.4:15.6 gelPETA EtOAcAc 4:2 1:1 2:1 73:27 gelPETA butanediol 4:4 13.9:1 13.9:1 95:5 sol di- OAcAcPETA 4:4 9.7:1 9.7:1 93:7 solPETA 4:4 6.6:1 6.6:1 90:10 gelPETA cyclohexane 4:4 16.8:1 16.8:1 95:5 sol dimethanol di-PETA di-OAcAc 4:4 8.0:1 8:1 90:10 gelPETA neopentyl 4:4 14.7:1 14.7:1 95:5 sol glycolPETA di-OAcAc 4:4 10.3:1 10.3:1 93:7 solPETA 4:4 7.0:1 7:1 90:10 gelPETA TONE 4:6 29.8:1 19.9:1 95:5 sol 0301 tri- OAcAcPETA 4:6 20.8:1 13.9:1 93:7 solPETA 4:6 14.1:1 9.4:1 90:10 gelPETA glycerin 4:6 18.6:1 12.4:1 95:5 sol tri-OAcAcPETA 4:6 12.1:1 8:1 92.5:7.5 gelPETA pentaery- 4:8 65.7:1 32.9:1 98:2 sol thritol tetra- OAcAcPETA 4:8 43.3:1 21.7:1 97:3 solPETA 4:8 32.2:1 16.1:1 96:4 solPETA 4:8 25.5:1 12.7:1 95:5 solPETA 4:8 17.8:1 8.9:1 93:7 gelPETA 4:8 12.1:1 6:1 90:10 gel______________________________________
Review of Table 4 shows that certain tetracrylate:acetoacetate ratios make sol or liquid oligomers of the invention.
In order to demonstrate ultraviolet light crosslinking of these liquid oligomers, samples containing 1% (wt) Irgacure 500 photoinitiator and 0% photoinitiator were applied to release liner and spread to a thickness of 1.5 mil. Specimens were cured on a Fusion Systems Corp. uv curing unit, using an H-bulb and belt speed of 20-25 feet/minute; all formed transparent, flexible, nearly colorless films. Samples of each film were weighed, immersed in acetone (a good solvent for the uncured resins) at room temperature for 48 hours, blotted dry and re-weighed to determine solvent uptake. Specimens were then dried to constant weight in a vacuum oven at 80° C. to determine gel fractions; these values are listed in the table 5 below.
TABLE 5______________________________________Solvent Uptake and Gel Fractions of UV Cured MethacrylateFunctional Polyesters. Solvent Solvent Uptake, % Gel Fraction Uptake, % Gel Fraction (Irgacure (Irgacure 500, (No Photo- (No Photo-DIACRYLATE 500, 1%) 1%) initiator) initiator)______________________________________NPG 18 94% 9 96%PEG 200 19 96% 18 94%Hexanediol 12 96% 9 96%Triethylene 16 95% 19 96%glycol______________________________________
These results confirm that the products are crosslinked and indicate no significant difference between products cured with or without added photoinitiator. This suggests that the pendant methyl ketone substituents serve as an internal or "built in" photoinitiator. To further demonstrate the role of methyl ketone substituents in the uv cure of these resins, three acrylate terminal resins were prepared from neopentyl glycol diacrylate and various b-dicarbonyl compounds in a 5:4 molar ratio. β-dicarbonyl compounds included acetylacetone (2 methyl ketones per molecule), ethyl acetoacetate (1 ketone/molecule) and diethyl malonate (no ketones). UV cure was performed as before, without added photoinitiator. Resins containing acetylacetone or ethyl acetoacetate cured to soft, tacky films. Such films are useful in protective or decorative coatings on wood, or metal substrates. The resin containing diethyl malonate failed to cure, remaining liquid. | The liquid oligomeric compositions of this invention are made by the Michael addition reaction of acetoacetate functional donor compounds with multifunctional acrylate receptor compounds where the equivalent ratios of multifunctional acrylate to acetoacetate vary from ≧1:1 to ≧13.2:1 depending on the functionality of both multifunctional acrylate and acetoacetate. Unuseable gelled or solid oligomer products occur below the claimed ranges. The liquid oligomers of this invention are further crosslinked to make coatings, laminates and adhesives. | 2 |
This application is a division of application Ser. No. 08/215,497, filed Mar. 18, 1994, now U.S. Pat. No. 5,491,637.
FIELD OF THE INVENTION
The present invention relates generally to the fields of manufacturing, handling and installing steel pipe. More particularly, the invention relates to a method of uniquely identifying each section of steel pipe and creating a comprehensive manufacturing, shipping and location history for each section of steel pipe.
BACKGROUND OF THE INVENTION
Steel pipe is typically manufactured at a mill one batch at a time commonly referred to as a heat. A single ladle of molten steel is used to form a slab or billet for a single heat. The slab or billet is then divided into smaller units commonly referred to as coils. Finally, each coil is further divided into several lengths or individual sections of pipe commonly referred to as joints. Therefore, each section of pipe can be uniquely identified by specifying the heat, coil and joint.
After pipe joints are manufactured, they are subjected to various tests prior to shipment. Pipe joints are then shipped to purchasers who receive the pipe and decide whether to accept it. Purchasers sometimes perform additional testing on pipe joints before they are accepted. After pipe joints are accepted, they are either stored for future use or installed directly in a pipeline or well bore. Accurate record keeping at each of these phases in the manufacturing process is essential to be able to accurately identify individual pipe joints for future operations.
In one known method of identifying pipe joints, each pipe joint is stenciled with identification information. This method of identifying pipe joints is subject to significant shortcomings, in some cases, because pipe joints are subjected to other processing that tends to remove stenciled information. Examples of these processes are internal or external coating, hot or cold bending, threading or grit blasting. The coating process typically removes the stencils. After coating, each pipe joint has to be re-stenciled. Thus, the possibility for error because of failure to re-stencil pipe joints with the correct information exists. Stenciled information also has a useful life of about six months. Therefore, stenciled information is not useful for long-term identification of pipe joints. Furthermore, stenciled information cannot be read at all after the pipe joint is deployed in a pipeline and buried or submerged in water.
In another known method of identifying pipe joints, a bar code label that embodies manufacturing information and identification information is disposed inside of each pipe joint. The bar code label remains in the pipe joint throughout its lifetime and is readable from either inside or outside the pipe joint. This method of identifying pipe joints is not effective because the bar code labels cannot be read accurately using existing technology. Scanning devices known in the art as "pigs" are deployed into completed pipelines to read the bar code labels with generally poor results. It is also undesirable in many cases to leave bar code labels inside pipe joints because the inside of the pipe joints must be scraped clean prior to installation. The use of bar coded labels inside pipe joins also leads to the possibility of valve jams and similar problems that occur because the bar code labels tend to loosen and become dislodged over time as fluid flows in the completed pipeline.
Paper records known in the art as tally sheets have been used to keep track of pipe joints at various stages of manufacturing, testing and shipping. Shortcomings in prior art pipe joint identification methods result in problems in maintaining accurate tally sheets. Specifically, prior art methods of identifying pipe joints are cumbersome, inefficient and subject to human error. These potentials for error are compounded by the manual labor intensive nature of creating tally sheets.
Impending Federal Department of Transportation regulations mandate that each section of pipe be uniquely identified and its manufacturing history recorded and saved. By continuing to use the typical manual labor intensive procedures for identifying each section of pipe and recording its history, these regulations will lead to more elaborate but still error-prone record keeping procedures on the part of manufacturers and users of steel pipe.
Another continuing problem in the field has been the difficulty of maintaining accurate testing, transportation and shipping records for pipe joints. This is true because the homogeneous nature of pipe joints makes it difficult to uniquely identify a specific joint. Moreover, steel pipe joints of similar grade have substantially similar characteristics regardless of where or by whom they were manufactured.
The ability to maintain accurate identification information for pipe joints is also desirable because catastrophic failure of pipe joints can result in legal liability for the owner of the pipe. If the pipe owner has evidence identifying the manufacturer of the pipe, the pipe owner has the opportunity to seek legal recourse against that manufacturer to limit his liability. Accurate identification information further allows the pipe owner to inspect pipe joints with similar histories (e.g. pipe joints from the same heat and/or coil) to prevent further catastrophic failures.
A method of creating a comprehensive manufacturing, shipping and location history for pipe joints is desirable. Such a method would result in simplified record keeping procedures and assist users of steel pipe joints in their duty of compliance with new government regulations. A method of creating a comprehensive manufacturing, shipping and location history would also allow substantial time savings in pipe shipping and receiving operations and allow accurate identification of installed pipe joints.
SUMMARY OF THE INVENTION
The present invention is a method of creating an accurate, comprehensive history for each pipe joint manufactured. This history preferably includes a purchase order number, a size, a weight, a grade, an end finish, a wall thickness, a manufacturing specification, an identification of the manufacturer, a date of manufacture, the specific heat number, the coil number and the joint number identifying the steel used to make the pipe joint. Each pipe joint is assigned a unique joint number. The length of the joint is also part of the history.
The method of the present invention employs a hand-held computer with a bar code label printer, a report printer and a bar code scanner. Manufacturing, testing, shipping and receiving data is entered into the hand-held computer by an operator at various stages in the manufacture of the pipe joints. When the pipe joints are shipped from the mill, bar code labels are generated for each pipe joint using the hand-held computer and the bar code label printer. The bar code label, which is preferably affixed to the inside of the associated pipe joint, includes all information from the history previously described for each pipe joint.
To create a shipping history, each bar code label from a pipe joint that is to be shipped is scanned into the hand-held computer using the bar code scanner. The identity of carrier, the mode of transportation and the destination of the shipment are preferably entered into the hand-held computer prior to shipment. The hand-held computer automatically tallies pipe joint information as pipe joints are loaded and informs the user when the carrier has reached its capacity. A bar code shipping label reflecting all historical information about the shipment is generated using the hand-held computer and the bar code label printer. The bar code shipping label typically accompanies the shipping documentation.
When the shipment is received, the receiver scans the bar code shipping label and compares the information contained therein to purchasing records. The historical information stored in the hand-held computer is also used to generate reports, which may be printed with the report printer. When each pipe joint reaches its final destination, its exact location is recorded as part of the historical record and the bar code is removed from the inside of the pipe joint.
The historical record created by the method of the present invention allows the manufacturer of each pipe joint to be easily identified. It also results in the ability to cross reference and identify pipe joints having similar characteristics in the event of a non-conformance during shipment or a catastrophic failure of a pipe joint after installation. Another advantage of the present invention is that the accurate, comprehensive information provided assists end users of pipe joints in receiving governmental and operational permits. The invention further facilitates compliance with the previously mentioned federal regulations. The invention provides information that is useful in performing the functions of inventory management and accounting.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings, in which:
FIG. 1 is a simplified block diagram of a computer system suitable for performing the method of the present invention;
FIG. 2 is a flow diagram of the overall functional hierarchy of a computer program capable of performing the method of the present invention;
FIG. 3 is a flow diagram showing the operations associated with the "exit to DOS" option of the present invention;
FIG. 4 is a flow diagram showing the operations associated with the system set-up option of the present invention;
FIG. 5 is a flow diagram showing the operations associated with the purchase order information option of the present invention;
FIG. 6 is a flow diagram showing the operations associated with the pipe labeling option of the present invention;
FIG. 7 is a flow diagram showing the operations associated with the pipe shipping option of the present invention;
FIG. 8 is a flow diagram showing the operations associated with the pipe receiving option of the present invention;
FIG. 9 is a flow diagram showing the operations associated with the reports option of the present invention;
FIG. 10 is a flow diagram showing the operations associated with the miscellaneous operations option of the present invention;
FIG. 11 is a flow diagram showing the operations associated with the pipeline tracking option of the present invention.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. On the contrary, the applicants' intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a simplified block diagram of a computer system suitable for performing the method of the present invention. A hand-held computer 10 is connected via a bus 12 to a bar code label printer 14, a report printer 16 and a bar code scanner 18. As will be fully set forth, the hand-held computer 10 is programmed to carry out the method of the present invention. The hand-held computer 10 may be of any conventional architecture and may operate using any conventional operating system. In a preferred embodiment, the hand-held computer 10 operates using the DOS operating system.
The hand-held computer 10 is used to receive and organize all information pertinent to performing the method of the present invention. Information is input into the hand-held computer 10 either manually or via the bar code scanner 18. The information managed by the hand-held computer 10 includes manufacturing data for pipe joints, purchase order data and transportation data. The bar code label printer 14 is used to print individual bar code labels containing manufacturing information for pipe joints. The bar code label printer 14 is also used to print bar code labels containing transportation information and manufacturing and other information for entire shipments of pipe joints.
In a preferred embodiment of the invention, two-dimensional bar codes of the type commonly known in the field are employed because they have the capability of recording sufficiently large quantities of information. It is contemplated, however, that any type of bar coding that allows recording of enough information is suitable for use in the invention.
The report printer 16 is used to print various reports using information stored in the hand-held computer 10. Examples of reports that may be generated from the information stored in the hand-held computer 10 are shipping tally reports, receiving tally reports, daily summary reports and receiving summary reports. The contents of these reports is fully explained below.
FIG. 2 is a flow diagram of the overall functional hierarchy of a computer program capable of performing the method of the present invention. At step 19, a user is asked to identify his unique user name. The user name is verified at step 20. If the user name is not valid, it must be re-entered by the user. At step 21, the user is required to enter a unique password. At step 22, the password is verified. If the password is not correct for the associated user name, the user must re-enter his user name and password. These functions are performed to allow unique identification of system users and to prevent unauthorized access to information stored on the hand-held computer 10. The functions of requiring a user to identify himself via a user name and a password are well-known to those of ordinary skill in the field.
After the entry of a valid user identification and password combination, a main menu is displayed to the user. The main menu displays the remaining option choices shown in FIG. 2. In a preferred embodiment of the present invention, the program that performs the method of the present invention allows the user to quit the program by logging off in a conventional manner.
An "exit to DOS" option shown at step 26 allows the user to exit the program that performs the method of the present invention and return to the operating system of the hand-held computer 10. The step 26 "exit to DOS" option allows the user to perform data manipulation functions using the operating system functions of the hand-held computer 10. The "exit to DOS" option shown at step 26 is fully explained below with reference to FIG. 3.
A system setup option shown at step 28 allows the user of the hand-held computer 10 to define system parameters based on specific requirements. The step 28 system setup option is fully explained below with reference to FIG. 4.
A purchase order information option shown at step 30 allows a user to enter purchase order information into the hand-held computer 10. The step 30 purchase order information option is fully explained below with reference to FIG. 5.
A pipe labeling option shown at step 32 allows the user to enter data for specific pipe joints into the hand-held computer 10 and to generate individual bar code labels for pipe joints using the bar code label printer 14. The step 32 pipe labeling option is fully explained below with reference to FIG. 6.
A pipe shipping option shown at step 34 allows the user to enter shipping and other transportation information into the hand-held computer 10 using the bar code scanner 18. The user may also generate a comprehensive shipping label bar code and/or a shipping tally report using the pipe shipping option. The step 34 pipe shipping option is fully explained below with reference to FIG. 7.
A pipe receiving option shown at step 36 allows the user to generate a report containing information relating a shipment of received pipe joints by scanning the comprehensive shipping label bar code generated at step 34 by the pipe shipping option with the bar code scanner 18. The received pipe joint information report may also be generated by scanning the individual bar code labels affixed to each received pipe joint in a shipment with the bar code scanner 18. The step 36 pipe receiving option is fully explained below with reference to FIG. 8.
A reports option shown at step 38 allows the user to generate a variety of pipe joint information reports from information stored in the hand-held computer 10 and print the results on the report printer 16. The step 38 reports option is fully explained below with reference to FIG. 9.
A miscellaneous operations option shown at step 40 allows the user to perform a variety of miscellaneous operations such as reprinting duplicate pipe labels. The step 40 miscellaneous operations option is fully explained below with reference to FIG. 10.
A pipeline tracking option shown at step 41 allows the user to create a record of the location of specific pipe joints in a pipeline. The manufacturing and transportation data recorded on the bar code label affixed to the pipe may be identified for each specific pipe joint in the pipeline. The step 41 pipeline tracking option is fully explained below with reference to FIG. 11.
FIG. 3 is a flow diagram showing the operations associated with the step 26 "exit to DOS" option of the present invention. If the user selects the "exit to DOS" option from the main menu, he is given the choice of manually entering data into the hand-held computer 10 using operating system commands as indicated at step 42 or deleting information from the hand-held computer 10 as indicated by step 44. When the user completes operating system functions at step 46, program control is returned to the main menu or any other menu shown in FIG. 2.
FIG. 4 is a flow diagram showing the operations associated with the system set-up option 28 of the present invention. The system set-up option is typically accessed when the hand-held computer 10 is initially set up or when system parameters require alteration because of changed system conditions. In other words, accessing the system setup option 28 is an unusual event that is normally performed by a system administrator rather than a typical end user. At step 48, entry of a unique system name is required. Entry of a unique system password is required at step 50. The system name and password must be entered before system parameters may be altered.
Alteration of the system name and password are not part of the method of the present invention. Moreover, the development of software to allow alteration of the system name and password is within the ability of one of ordinary skill in the field.
After the correct system name and password have been entered, the system date (step 52) or the system time (step 54) may be changed. The number of system users may be modified as shown at step 56. After the number of users is defined, individual user names may be changed as shown at step 58. Similarly, individual user passwords may be changed as shown at step 60. Upon completion of the system set-up option 28, as shown at step 62, program control is returned to the main menu or any other menu shown in FIG. 2.
FIG. 5 is a flow diagram showing the operations associated with the purchase order information option 30 of the present invention. The purchase order information option 30 allows the user to perform two functions related to purchase orders. The first allows the entry of purchase order information for pipe joints that will be manufactured, labeled and shipped, as indicated at step 64. As will be explained, the user defines the purchase order number, the size, the weight and thickness of the pipe joints ordered. Purchase order information is required to generate individual pipe bar code labels using the pipe labelling option 32.
The second function is the entry of heat and coil information, as shown at step 66. Heat and coil information are unique identifiers given to the heat and coil of steel used to manufacture the pipe for the purchase order. Heat and coil information is also required for the generation of pipe joint bar code labels using the pipe labelling option 32. Purchase order information must be entered into the hand-held computer 10 before heat and coil information is entered. When performing the pipe labelling option 32, purchase order information is used to ensure that duplicate pipe joint bar code labels are not accidentally generated by the user.
When entering purchase order information (step 64), the user must define a purchase order number 68, an item number 70, a purchase order date 72, a manufacturer 74, a size 76, a weight 78, a wall thickness 80, a manufacturing process 82, a grade 84 and an end finish 86.
When the user has completed the entry of purchase order information, he may proceed directly to the entry of heat and coil information 66. Alternatively, the user may exit the purchase order information option 30 as shown at step 87 and enter the heat and coil information for the purchase order at a later time. If the user exits the purchase order information option 30 as indicated at step 87, program control is returned to the main menu or any other menu shown in FIG. 2.
When performing the entry of heat and coil information at step 66, the user is required to select a purchase order number at step 88 and to select an item number at step 90. A purchase order may contain a variety of item numbers. Item numbers typically correspond to different sizes of pipe. Different sizes of pipe joints may be ordered using different item numbers on the same purchase order. Next, the heat number 92 and coil number 94 are entered for each item number. Each line item of a purchase order may call for pipe joints that are made from more than one heat and coil. The hand-held computer 10 allows entry of any number of heat and coil entries for each purchase order line item.
When the purchase order information option 30 is initiated, the user is prompted for a purchase order entry and a purchase order number. When this information is entered, the program executing the method of the present invention determines whether the purchase order is new or whether information has previously been entered for it. If the purchase order is new, the hand-held computer 10 prompts for the purchase order date and the manufacturer. If the purchase order has previously been entered, the hand-held computer 10 re-displays the values that were previously entered. When the user has finished entering purchase order information as shown at step 96, program control may return to the main menu or any other menu shown in FIG. 2.
FIG. 6 is a flow diagram showing the operations associated with the pipe labeling option 32 of the present invention. The pipe labeling option 32 allows the user to enter information about pipe joints that were manufactured and accepted for shipment. The pipe labelling option 32 cannot be used until purchase ordering information has been entered into the hand-held computer 10.
When the pipe labelling option 32 is initiated, the user is prompted for a purchase order number as shown at step 98 and item number as shown at step 100. The purchase order number and item number must match information previously entered into the hand-held computer 10. Once the purchase order number and item number have been properly selected, the user is prompted for information identifying each pipe joint accepted for shipment. If previous pipe joints have been entered using the pipe labelling option 32, the user is prompted to enter additional pipe joints. Thus, the user may enter information for several pipe joints then perform other functions before returning to the pipe labelling option 32 to complete entry of information for a specific purchase order and item number.
To uniquely identify a pipe joint, the user must enter a coil number as shown at step 102, which is automatically associated with a specific heat number (step 104) entered during the purchase order information option 30. The coil number and heat numbers must match coil and heat numbers previously entered for the purchase order using the purchase order information option 30. In a preferred embodiment of the invention, the coil number defaults to the previously-entered coil number because the coil number changes infrequently. The default coil number is edited when it does change.
After the coil number and heat number have been properly identified, the user decides whether the pipe joint is accepted for shipment as shown in step 106. This determination is made based on whether the joint meets the standards to which it was manufactured. If the pipe joint is not accepted, it is not labelled (step 108). Accordingly, the user proceeds to the next pipe joint to determine whether it is accepted as shown at step 110.
If the joint is accepted for shipment, the user inputs a unique joint number as shown at step 112 and the length of the joint as shown in step 114. In a preferred embodiment, duplicate joint numbers are not permitted. Also in a preferred embodiment, a program embodying the method of the present invention allows the user to edit the joint length at any time. This feature is desirable because pipe joints are sometimes divided into smaller units for installation in a pipeline or well bore. If a joint is so divided, additional labels may be generated by creating duplicate records, editing the length for each smaller section and printing additional labels. Thus, if a single joint is divided into three smaller sections for installation, three separate labels may be generated, each indicating the correct length for the associated joint section with all other information on the label remaining the same for each of the three smaller sections.
The history of the present invention may also include manufacturing specifications, as previously noted. These specifications include the results of tests performed on pipe joints during manufacture. Thus, the history of the present invention allows future identification of tests performed on individual pipe joints.
Next, the user has the option of printing the bar code label for the pipe joint as shown at step 116 or continuing to enter information for other pipe joints. If the user desires to print the bar code label, it is printed as shown at step 118 using the bar code label printer 14. Subsequently, the bar code label is affixed to the pipe as shown at step 120. If the user desires to continue entering information for additional pipe joints as shown at step 121, program execution returns to step 106. In a preferred embodiment of the present invention, bar code labels based on information entered in the pipe labelling option 32 at a later time using the reports option 38. When the user exits the pipe labelling option 32 as shown at step 122, program control may return to the main menu or any other menu shown in FIG. 2.
The pipe labelling option 32 of the present invention greatly improves record keeping ability. Data is entered and maintained in the hand-held computer 10 for each specific pipe joint that is accepted for shipment. This data may be edited if errors are made. Unique bar code labels are generated for each pipe joint and labels containing identical information are prohibited with the exception that the user is given the option to print a duplicate pipe label if the original label is lost or damaged. Thus, each pipe joint accepted for shipment is uniquely identified by its own bar code label.
FIG. 7 is a flow diagram showing the operations associated with the pipe shipping option 34 of the present invention. The pipe shipping option 34 allows a user to enter the number of pipe joints that are being loaded onto a truck, rail car, barge, ship or any other mode of transportation. When the pipe shipping option 34 is initiated, the user must enter a carrier identification as shown at step 124 and a shipping method as shown at step 126. The user must also enter a "ship from" location as shown at step 128 and a "ship to" location as shown at step 130.
The carrier identification is used to uniquely identify each shipping transaction. Specifically, the carrier identification uniquely identifies the mode of transportation being loaded for shipment. In a preferred embodiment of the invention, the carrier identification is checked to determine whether shipping information is being entered for the first time or whether additional shipping information is being entered for a previously-entered carrier identification. If the shipping information being entered is not for a new carrier identification, the user is not required to enter the shipping method, "ship from" location or "ship to" location.
Next, the user scans the individual bar code labels for each pipe that is to be shipped using the bar code scanner 18 as shown at step 132. If a bar code label for a pipe joint cannot be located or for some reason cannot be scanned with the bar code scanner 18, information for the corresponding pipe joint may be manually entered into the hand-held computer 10 as shown at step 134. If pipe joint information must be manually entered, the joint number and its length must be known. Additionally, a bar code label corresponding to a pipe joint manufactured for the same purchase order number and item number must be available to be scanned. The joint number and coil number are manually entered and the remaining information for the missing entry is entered into the hand-held computer 10 by scanning the label of the pipe joint that was manufactured for the same purchase order number and item number.
In a preferred embodiment of the invention, an error will be indicated if a label is accidentally scanned more than once or if duplicate labels are scanned for a given shipment of pipe joints. The program performing the method of the present invention maintains a running total of the number of pipe joints scanned.
If the shipping method is by truck, a running total of all pipe joints to be shipped is maintained. An indication is given by the hand-held computer 10 when the total weight of pipe joints to be shipped exceeds a predetermined weight (for example, 45,000 pounds). A preferred embodiment of the present invention also gives the user an opportunity to enter any remarks pertinent to the specific shipment being entered.
After all bar code labels for pipe joints to be shipped have been scanned, the user has the option to print a shipping tally report using the report printer 16 as shown at step 136. If the user elects to print the shipping tally report, the report is printed as shown at step 138. A preferred embodiment of the shipping tally report includes all information that has been entered into the hand-held computer 10 that is pertinent to the particular purchase order. The shipping tally report also preferably includes a total count of pipe joints shipped, a total weight of all pipe joints shipped and a total length of all pipe joints shipped. Those of ordinary skill in the field will recognize, however, that the shipping tally report may contain any desired subset of the purchase order information. The organization and layout of the shipping tally report is not an essential feature of the invention.
The user also has the opportunity to print a bar code shipping label as shown at step 140. If the user desires to print the bar code shipping label, the label is printed using the bar code label printer 14 as shown at step 142. In a preferred embodiment of the invention, a separate bar code shipping label is generated for each purchase order item to be shipped. The bar code shipping label contains a simplified manifest of the purchase items that are to be shipped. The specific items recorded in the bar code shipping label are not an essential feature. Moreover, those of ordinary skill in the field will recognize that any suitable combination of items may be selected to be recorded in the bar code shipping label. When the pipe shipping option 34 has been completed as shown at step 144 program control may return to the main menu or any other menu shown in FIG. 2.
FIG. 8 is a flow diagram showing the operations associated with the pipe receiving option 36 of the present invention. The pipe receiving option 36 allows the user to enter information about pipe joints that are received into the hand-held computer 10. If a shipment of pipe joints is accompanied by a bar code shipping label produced using the pipe shipping option 34, receiving information is entered into the hand-held computer 10 by scanning the bar code shipping label with the bar code scanner 18 as shown at step 146. The user compares the information from the bar code shipping label with what was actually ordered on the associated purchase order as shown at step 148. If the information on the bar code shipping label corresponds to the pipe joints that were ordered, the shipment is accepted as shown at step 150. If the information from the bar code shipping label does not correspond to the pipe joints that were actually ordered, the shipment is rejected as shown at step 152.
The ability to enter all receiving information by scanning the bar code shipping label greatly reduces the amount of time required to determine whether a shipment of pipe joints should be accepted. Additionally, information read from the bar code shipping label is not subject to human error. Accordingly, the method of the present invention results in significant cost savings and is more accurate than prior art methods.
If no bar code shipping label is provided with the shipment, information is manually entered into the hand-held computer 10 as shown at step 154. A carrier identification, shipping method, "received from" location and "shipped to" location are manually entered into the hand-held computer 10 as shown at steps 156, 158, 160 and 162 respectively. Next, the individual bar code labels affixed to each pipe joint in the shipment are scanned as shown at step 164. The total number of joints is determined as shown at step 166. The receiving information is then compared to the actual purchase order information as shown at step 168. If the receiving information is correct, the shipment is accepted as shown at step 170. The shipment is rejected as shown in step 172 if the receiving information does not match what was actually ordered.
In the pipe receiving option 36, the user has the option to print a receiving tally report based on the information entered into the hand-held computer 10 either by scanning the bar code shipping label or by scanning the bar code label affixed to each individual pipe joint received. This report is useful in identifying pipe joints that were either not included in the shipment or included erroneously.
FIG. 9 is a flow diagram showing the operations associated with the reports option 38 of the present invention. The reports option 38 allows the user to print or reprint bar code labels for individual pipe joints as shown at step 174. These labels are printed based on information entered into the hand-held computer 10 using the pipe labelling option 32.
The reports option 38 also allows the user to print a shipping tally report and a bar code shipping label as shown respectively at steps 176 and 178. The shipping tally report and bar code shipping label are created based on information entered into the hand-held computer 10 using the pipe shipping option 34.
As shown at step 180, the reports option 38 allows the user to print a receiving tally report. The receiving tally report is created based on information entered into the hand-held computer 10 using the pipe receiving option 36.
The reports option 38 further allows the user to print a daily summary report as shown at step 182. The daily summary report gives information about pipe joints that have been manufactured or labelled on a given day. In a preferred embodiment, the user selects the option of printing the daily summary report and identifies a purchase order number and item number. The daily summary report preferably includes the heat number, coil number, joint number, joint length and joint weight. The daily summary report is preferably sorted by labelled date, heat number, coil number and joint number.
Finally, the reports option 38 allows the user to print a receiving summary report as shown at step 184. The user selects the receiving summary report option and identifies a purchase order number and item number. The receiving summary report preferably includes the carrier, the total number of joints shipped by that carrier and the total length and weight of pipe joints shipped by that carrier for each carrier that shipped pipe joints for the identified purchase order number and item number. When the user desires to terminate the reports option 38 as shown at step 186, program control may return to the main menu or any other menu shown in FIG. 2.
FIG. 10 is a flow diagram showing the operations associated with the miscellaneous operations option 40 of the present invention. The miscellaneous operations option 40 allows the user to perform special functions that do not normally occur during the pipe labeling, shipping and receiving process.
As shown at step 188, the miscellaneous operations option 40 allows the user to delete pipe joint information that was scanned into the hand-held computer 10 using the pipe shipping option 34. If the bar code label for a pipe joint is scanned into the hand-held computer 10 and the pipe joint is not actually loaded onto the carrier or the joint is removed because of damage during loading or other reasons, the information about the pipe joint that was not loaded or was removed must be deleted from the hand-held computer 10 to ensure accuracy of the bar code shipping label and the shipping tally report.
The miscellaneous operations option 40 also allows the user to create duplicate pipe labels as shown at step 190. This feature may be used to create a duplicate pipe joint bar code label by scanning the existing label with the bar code scanner 18. Also, the duplicate pipe label feature allows the user to create a missing label by scanning a similar bar code label with the bar code scanner 18 and editing information such as the joint number and length before printing the new bar code label. No other information must be present in the hand-held computer 10 to use the duplicate pipe label function. When the user desires to terminate the miscellaneous operations option 40 as shown at step 192, program control may return to the main menu or any other menu shown in FIG. 2.
FIG. 11 is a flow diagram showing the operations associated with the pipeline tracking option 41 of the present invention. The pipeline tracking option is an extremely important aspect of the present invention because it allows accurate identification of pipe joints after they have been installed in a pipeline or well bore based on information entered into the hand-held computer 10 during the various stages of manufacture and transportation.
When a pipe joint is installed in a pipeline or well bore, information previously entered into the hand-held computer 10 is maintained as a record and the bar code associated with that pipe joint is removed. Creation of a permanent record and removal of the bar code from the inside of pipe joints allows the important advantages over known bar code tracking systems. Removal of the bar code prevents subsequent valve jams and other similar problems that occur over time when bar codes become dislodged because of fluid flow in the pipeline. The permanent record created in the hand-held computer 10 is used to specifically identify individual pipe joints in a completed pipeline or well bore. The permanent record can be used to identify the manufacturer of specific pipe joints in the pipeline or well bore in the event of catastrophic failure of one of the pipe joints so that the legal liability of the owner of the pipeline or well bore may be shared with the manufacturer of the pipe joint that failed. Additionally, other pipe joints having similar manufacturing characteristics may be identified and examined to ensure that other catastrophic failures do not occur.
The pipeline or well bore tracking option 41 allows the user to define a pipeline or well bore as shown in step 194. To identify a pipeline or well bore, the user is required to enter a pipeline or well bore name and an appropriation or project number. After this information is entered into the hand-held computer 10, the user is allowed to enter information to track individual pipeline or well bore joints as shown at step 196. The user may enter specific pipe joint information either manually or by scanning the bar code label associated with a particular pipe joint. The user also enters the specific location in the pipeline or well bore that the pipe joint occupies based on its physical location (for example, the latitudinal and longitudinal or vertical coordinates of the pipe joint) or its location in terms of how many joints it is removed from a specific point in the pipeline or well bore.
Finally, the user is allowed to print a pipeline tracking .report as shown in step 198. The pipeline tracking report includes information sufficient to identify each individual pipe joint based on its location in the pipeline or well bore. Thus, the pipeline tracking report allows identification of specific pipe joints based on relevant manufacturing and transportation characteristics as recorded using the purchase order information option 30, the pipe labelling option 32, the pipe shipping option 34 and the pipe receiving option 36 of the present invention. When the user desires to terminate the pipeline tracking option 41 as shown at step 200, program control may return to the main menu or any other menu shown in FIG. 2.
The method of the present invention has numerous other uses as well. For example, the historical record of information that results from the method of the invention may be analyzed to predict catastrophic failures of pipe joints. If a pipe joint fails, the historical record may be evaluated to determine the location of other pipe joints having similar characteristics. When these pipe joints have been identified, they may be subjected to examination and testing to determine whether they should be replaced.
The record of information created by the method of the present invention may additionally be used to identify inconsistencies in the manufacturing processes used by producers of steel pipe. Pipe joint numbers are typically assigned sequentially based on the relative position of the joint within the associated coil during manufacture. Inconsistencies in the manufacturing process usually cause joints in similar relative positions in different coils to have similar characteristics. For example, if joint number seven in a first coil is defective, it would not be unusual for the joint in the same position in a different coil made with the same process to be similarly defective. The historical record created by the method of the present invention may be analyzed to identify the existence of these types of manufacturing process inconsistencies. This information is useful for assisting producers of steel pipe joints in improving their manufacturing processes.
Thus, there has been described herein a method of creating a comprehensive manufacturing, shipping and location history for pipe joints. It will be understood that various changes in the details and arrangements of the implementation described herein will occur to those skilled in the art without departing from the principle and scope of the present invention. While the invention has been described with reference to the presently contemplated best mode for its practice, it is intended that this invention only be limited by the scope of the appended claims. | A method of determining the number of a plurality of pipe joints that can be shipped on a transportation means without exceeding a predetermined weight is set forth. The method employs a bar code reader coupled to a computer and involves initially determining the weight of each pipe joint. After this determination, a bar code label, which includes the weight of the pipe joint, is affixed to the pipe joint. The predetermined weight for the transportation means is then entered in the computer and the bar code for each pipe is scanned as it is placed on the transportation means. The computer calculates the running total of the weight of the pipe joints which have been scanned and compares that calculated weight to the predetermined weight. When the predetermined weight for the transportation means has been exceeded, the operator is notified. | 4 |
[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 60/651,762, filed Feb. 11, 2005
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to the use of communication protocols within computerized devices, and in particular to modules that emulate one protocol on top of another protocol.
[0003] Computers and components communicate by sending and receiving electrical signals that represent data in the form of bits. The interfaces used for such communication are roughly categorized into serial interfaces, in which a single bit is transferred at a time, and parallel interfaces, in which multiple bits are transferred concurrently. Parallel interfaces vary in the number of data bits that are transferred concurrently, which can be considered to be the “breadth” of the interface; i.e. a sixteen-bit interface is “broader” than a four-bit interface, and the narrowest interface is obviously the serial interface that moves a single bit at a time.
[0004] Broader interfaces offer, potentially, a higher flow-rate of data, but require multi-wire connecting cables and circuits. This makes them more suitable for internal communication among computer components; accordingly the standard data bus of most computers uses parallel interfaces of 16-64 bits. Another important advantage of a parallel interface is in its being suitable for RAM protocols that run applications directly from memory, and specifically boot code protocols that initialize the fundamental functionalities of a computer or a computerized appliance upon the appliance being connected to a power source. When connecting a computer to external or detachable components, such as peripherals or memory cards, the size and reliability of the connectors and cables become a primary consideration, which pushes connections to peripherals or detachable components toward narrower interfaces, often serial interfaces.
[0005] Three commonly-used narrow interfaces for connecting external devices or detachable components that have been standardized by the computer industry are Universal Serial Bus (USB) that is a serial interface, MultiMediaCard (MMC) that is a narrow interface of one to eight bits, and SecureDigital (SD) that is a narrow interface of one to four bits. These standards define physical, electrical and logical characteristics that ensure efficient and reliable data transfer between devices that implement the standards.
[0006] When a computer or computerized appliance uses a bus of 16-64 bits internally and communicates externally through narrower buses of, typically, 1-8 bits, protocol converters, usually in the form of hardware components or subcomponents, are included to transform one communication protocol to another.
[0007] FIG. 1 illustrates an exemplary system 100 of the background art, wherein a host 110 , for example a personal computer or computerized appliance, is connected to a peripheral storage device 130 via a USB link 126 . A USB link, under the USB standard, uses four wires, but only one data bit is transferred at a time. Host 110 has a CPU (central processing unit) 112 that is configured by applications and drivers (not shown) to send storage-related commands, such as read and write commands, to storage device 130 . Such commands leave CPU 112 on an internal bus 124 that is designed according to the architecture of internal computer buses for communication between CPU 112 and all internal components (e.g. hard disk, optical drive, modem, network card, etc.), and that is usually a broad parallel interface of 16 to 64 bits. A host controller 116 converts the commands that have been received from CPU 112 into a serial USB protocol in order to send the commands through a serial USB link 126 . When received by a client controller 134 , the commands are transformed by controller 134 to commands transferred through a parallel communication link 144 , for executing the actual storage-related operations on a storage module 136 . Controller 134 contains a communication controller 138 and a storage management controller 132 . It will be noted that controller 134 is representative of all components of storage device 130 that include processing capability, and may be implemented as a single or multiple physical units.
[0008] The popularity of external peripherals and detachable components has pushed many popular software modules, component designs and commercial components toward narrower communication interfaces, such as USB or MMC. A special situation of interest arises, however, when a designer of an appliance is attracted by the performance, standardization, availability or cost of a design adapted for a protocol of a narrow interface such as USB or MMC, while wishing to fix that component permanently within an appliance. In such a situation, the benefits of narrow interfaces for external connections or detachability become irrelevant, and the employment of hardware protocol converters that are customarily used for detachable or externally-connected components implies extra complexity, cost, space, and possibly also degraded performance.
[0009] There is thus a need for solutions that allow integrating component designs originally adapted for narrow interfaces, into appliances that use a broader communication interface, without the need for protocol conversion by hardware.
SUMMARY OF THE INVENTION
[0010] As understood herein, a “broad” or “narrow” protocol is a protocol intended for use with a “broad” or “narrow” physical interface. “Breadth”, in this context, is defined as the number of bits exchanged concurrently: a 16-bit interface or protocol is twice as broad as an 8-bit protocol.
[0011] As understood herein, an “appliance” is any standalone computerized device, including, for example, a personal computer of any size and form, a mobile telephone, a two-way pager, a digital camera and a digital music player. As understood herein, a “component” is a part of an appliance that has a distinct role in the appliance.
[0012] According to the present invention there is provided an appliance including: (a) a physical interface for communication according to a first protocol; (b) a first functional component adapted to communicate via the physical interface; and (c) a second functional component including: (i) a functional module adapted to communicate using a second protocol that is narrower than the first protocol, and (ii) an emulation module for transforming between the first and second protocols to enable the first and second functional components to communicate with each other using the physical interface.
[0013] According to the present invention there is provided a component, for an appliance that includes a physical interface that uses a first protocol and a central processing unit that communicates via the physical interface, the component including: (a) a functional module adapted to communicate using a second protocol that is narrower than the first protocol; and (b) an emulation module for transforming between the second protocol and the first protocol to enable the central processing unit and the component to communicate with each other using the physical interface.
[0014] According to the present invention there is provided a central processing unit, for an appliance that includes a physical interface that uses a first protocol and a component that communicates via the physical interface, the central processing unit including: (a) a functional module adapted to communicate using a second protocol that is narrower than the first protocol; and (b) an emulation module for transforming between the second protocol and the first protocol to enable the central processing unit and the component to communicate with each other using the physical interface.
[0015] An appliance of the present invention includes a physical interface for communication according to a first protocol and two functional components. The first functional component is adapted to communicate via the physical interface. The second functional component includes a functional module adapted to communicate using a second protocol, such as a USB protocol, a MMC protocol or a SD protocol, that is narrower than the first protocol. The USB protocol is an example of a second protocol that is a protocol of a serial interface. To enable the two functional components to communicate with each other using the physical interface, the second functional component also includes an emulation module for transforming between the two protocols.
[0016] Preferably, the second functional component is a central processing unit of the appliance and the first functional component is a data storage device such as a flash memory data storage device. Alternatively, the second functional component is a data storage device such as a flash memory device and the first functional component is a central processing unit of the appliance.
[0017] Preferably, the physical interface is a random access interface.
[0018] The scope of the present invention also includes the second functional component separately, for example as a central processing unit of the appliance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
[0020] FIG. 1 is a schematic block diagram of a background art device and host;
[0021] FIGS. 2 and 3 are schematic block diagrams of systems of the present invention;
[0022] FIG. 4 is a schematic block diagram of a specific example of the system of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention is of a computer system and system component in which logical emulation of a standard communication protocol is used in conjunction with a physical interface that is broader than the physical interface supported by the protocol. Specifically, the present invention can be used to implement component designs originally intended for USB, MMC or SD communication through a broader communication interface.
[0024] The principles and operation of data exchange within a computer system according to the present invention may be better understood with reference to the drawings and the accompanying description.
[0025] The invention benefits from the ubiquity, reliability, cost and availability of component designs or software modules originally prepared under the logical characteristics of a ubiquitous standard narrow communication protocol (such as USB or MMC), while also benefiting from the advantages of a broader communication protocol, such as improved performance, code execution from memory, and boot from memory.
[0026] This object of the present invention is met by adding an emulated protocol converter (“emulator”) to a system which for example may include a CPU and a memory device. The emulator of the present invention is configured to receive commands that comply with the standard logical characteristics of a communication protocol for a narrow communication link and to transmit these commands over a different, broader communication link. For example, if the communication protocol is the USB protocol then the present invention uses, with the USB protocol, a communication link that allows the passing of more than one bit concurrently. The positioning of the emulator with regard to the other components in the system varies in different embodiments of the present invention. The preferred embodiments shown in FIGS. 2 and 3 illustrate some options for positioning the emulator relative to the other system components.
[0027] Returning now to the drawings, FIG. 2 illustrates an appliance 200 according to a first preferred embodiment of the present invention. An appliance CPU 205 is a processor configured to run various appliance functions 210 , such as operating system services, drivers, user applications and/or dedicated functionalities such as picture taking, voice recording, telephony or music playing, according to the nature of appliance 200 . For example, component 220 may be a non-volatile memory device such as a flash memory device. Specifically, appliance functions 210 make use of a component 220 that is permanently or semi-permanently embedded within appliance 200 . Appliance functions 210 include software modules that have been programmed to cooperate with component 220 presuming that that component 220 uses a narrow protocol, e.g. a USB protocol. However, the actual communication link 226 between CPU 205 and component 220 uses a broader protocol than that presumed by the appliance functions 210 that use component 220 . The discrepancy between the protocols is resolved by an emulation module 215 that logically interfaces between appliance functions 210 and component 220 so that, while appliance functions 210 still send and receive commands to and from component 220 based on a narrow protocol, emulation module 215 ensured that such commands are properly converted, on their way to and from component 220 , so that component 220 communicates using the protocol of link 226 .
[0028] It will be appreciated that, in principle, appliance functions 210 could have been designed to use the broader protocol of link 226 for communicating with component 220 , thus obviating the need for emulation module 215 . However, the present invention allows using an available, advantageous design of appliance functions 210 , that were originally designed, for one reason or another, for narrower communication, to be utilized within the present configuration without being modified. Thus, emulation module 215 of the present invention, that is external to appliance functions 210 , allows using an available module originally designed for a narrower protocol, without appliance functions 210 being aware of the different protocol of component 220 . Similarly, component 220 designed for the broader communication of link 226 , is unaware of the actual narrower protocol which is actually used by appliance functions 210 .
[0029] FIG. 3 illustrates an alternative preferred embodiment of an appliance 300 , in which the standardized, narrow protocol is a characteristic of a component 310 , whereas an appliance CPU 305 is the appliance component that uses a broader protocol. Component 310 , in the present embodiment, is smart, in the sense that component 310 includes a programmable controller (not shown) for its functionality. Component functions 320 of component 310 include hardware and software for providing a useful service to appliance CPU 305 . Component functions 320 are designed to receive and send data through a narrow communication channel, such as USB or MMC. However, the actual communication link 326 between component 310 and appliance CPU 305 , is broader than that for which component functions 320 were designed. To overcome this discrepancy, emulation module 315 , that is preferably a software code that runs on the controller of component 310 , transforms the data flowing both ways between component functions 320 and appliance CPU so that appliance CPU 305 “sees” only the broader communication protocol it is designed for, while component functions 320 “see” only the narrower protocol they expect.
[0030] It will be noted that emulation modules 215 are 315 contain software code modules executing on processors that already exist in the respective implementations (CPU 205 and the controller of component 310 ). It will be appreciated that these emulation modules allow the respective appliance, 200 and 300 , to include components or software modules that have been originally designed for a narrow communication protocol, within an environment that employs a broader communication protocol.
[0031] FIG. 4 illustrates the embodiment of FIG. 3 implemented in a modified version of the prior-art example of FIG. 1 . Thus, the designer of an appliance 500 selects to embed, as a fixed component and with minimum modifications, the design of removable storage device 130 of FIG. 1 . However, the use of USB link 126 makes no sense under the present fixed configuration, thus rendering host controller 116 redundant. However, the designer of appliance 500 wants to minimize the modifications to the existing components of storage device 130 . As an additional benefit, a main communication bus 526 of appliance 500 supports RAM protocol that allows running programs, and especially booting appliance 500 from a boot program memory 550 .
[0032] A storage component 530 retains the main design elements of storage device 130 of FIG. 1 , including storage module 136 , storage management module 132 , and even USB communication module 138 (possibly with some modifications). However, USB communication module 138 is unsuitable for interfacing with broader communication link 526 . For that reason, storage component 530 includes an emulator module 532 in controller 534 . Accordingly, any data received by controller 534 via broad communication link 526 is transformed by controller 534 to USB commands that can be further processed by controller 534 , under the instructions of storage management module 132 , into operations on storage module 136 . Conversely, all data received by controller 534 from storage management module 132 are transformed by controller 534 through emulation module 532 , for transmitting over the broader communication link 526 .
[0033] Storage component 530 also includes a boot program memory 550 , to take advantage of the support by bus 526 of the RAM protocol that allows booting from storage component 530 . For example, in one exemplary embodiment of the present invention, storage component 530 is configured as described in the commonly-owned co-pending patent application titled NAND FLASH MEMORY SYSTEM ARCHITECTURE, which patent application is incorporated by reference for all purposes as if fully set forth herein. Storage module 136 is a NAND flash memory in which boot code for appliance 500 is stored. Boot program memory 550 is a SRAM. On power-up, controller 534 copies the boot code from storage module 136 to boot program memory 550 and appliance CPU 512 executes the boot code from boot program memory 550 .
[0034] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. | An appliance includes a physical interface for communication according to a broad protocol and two functional components. The first functional component communicates via the physical interface. The second functional component includes a functional module adapted to communicate according to a narrow protocol and an emulation module that transforms between the two protocols so that the two functional components can communicate with each other using the physical interface. | 6 |
FIELD OF THE INVENTION
This invention relates to a novel gin saw stand for ginning seed cotton. In particular, this invention relates to a gin saw stand having a powered roll box door and an adjustable seed roll retaining member that allow for adjustment of the shape of the roll box during operation of the gin saw stand and for automatic extension to retain the seed roll when the breast is opened.
BACKGROUND OF THE INVENTION
The process of picking cotton and removing seeds, trash and other foreign materials from the seed cotton is well known. Freshly picked seed cotton is transported from the field to a cotton gin. The cotton gin has apparatus for receiving the seed cotton, removing the seeds from the long cotton fiber or lint, cleaning the lint, and pressing the lint into bales for sale and further processing.
Central to this process is a saw type gin stand (referred to herein as a gin saw stand or gin). The gin saw stand separates the cotton fiber from the seeds. Before the seed cotton is fed into the gin saw stand, it is processed with other apparatus to remove heavier foreign materials such as rocks and larger sticks, etc., and dried to desired moisture levels. After drying and cleaning, the seed cotton is fed at a controlled rate into a gin saw stand. From the gin saw stand, the cotton fiber is next transported to lint cleaners for further cleaning or processing before bailing.
A commercial gin saw stand which is currently in use is shown in cross section in FIG. 1 . Referring to the figure, conventional gin saw stands 10 typically comprise an inlet cotton chute 11 wherein the cotton is deposited. A gin saw cylinder 12 , composed of a large number of spaced apart circular blades 13 rotating having serrated outer edges 15 about a common axis 14 , is combined with operably associated ribs 26 positioned between the blades 13 of the saw in order to strip the lint from the seed.
Delivery of the seed cotton into contact with the teeth of the first saw is assisted by a rotating toothed cylinder, referred to as the picker roller 21 , which throws the cotton from the inlet cotton chute 11 onto the saw 12 . This picker roller 21 is generally positioned with its axis 22 approximately lateral to the axis 14 of the saw 12 , with its outer periphery 23 spaced apart from the serrated outer periphery 15 or teeth of the saw 12 . The locks of cotton are drawn upwardly by the saw 12 , through a passage called the seed discharge shaft 31 and into the lower portion of a roll box 25 positioned above the axis 14 of the saw 12 where the seeds with attached cotton accumulate in a large mass. This mass of seeds and/or seed cotton is commonly referred to as the roll or seed roll (not shown in FIG. 1 ). Most of the interior of the seed roll is made up of lint-free seed, and the exterior primarily comprises partially ginned seed and un-ginned seed.
The roll box 25 is typically of somewhat distorted cylindrical configuration and its structure is shaped by the exposed, inwardly facing (relative to the roll box) surfaces of a plurality of different members of the gin saw stand 10 , such as, in the illustrated example, the upper portions 26 a of the ginning ribs 26 , the upper rib support 34 , one or more upper gin-side sheet members 38 (which may further comprise the inner surface 37 of door member 36 ), one or more concave partition or sheet members 39 of the breast 18 and adjustable sheet member 20 . Prior art gin saw stands 10 did employ an adjustable sheet member 20 though previously such sheet members have had a very limited degree of actuation, limited to the function and path of travel as that obtained with the cam shaft assembly as discussed herein. Prior art sheet members 20 did not serve the function of retaining the seed roll with in the roll box as is accomplished by the greater range of motion of the seed roll retaining member of the present invention (discussed below).
In some prior art gin saw stands (not shown), the roll box may also comprise an alternate additional set of ginning ribs for one or more additional saw cylinders.
While the roll box door member 36 of some prior art gin saw stands 10 do not form part of the roll box 25 , it is not uncommon for at least a portion of the roll box 25 to be formed by the concave inner surface 37 of the roll box door member 36 as illustrated in FIG. 1 . Typically there is a gap or space 35 in the upper portion of the roll box 25 to allow the seed roll to be viewed or even touched as the gin is operating. It will be noted that at the gap 35 , the seed roll will maintain its generally circular shape because the centrifugal force will tend for it to move horizontally at this point, but gravity and the cohesive qualities of the fibers within the exterior regions of the seed roll tends to pull it down.
As gin saw capacities have increased, gin saw stands have become wider. At the same time, the increased capacities and density of the seed rolls within these larger machines have resulted in the need for the reinforcement of the roll box surfaces shaping the seed roll. As a result, the surfaces forming the roll box, including the roll box door member 36 , have been made sturdier and more rigid, and thus thicker and heavier. This has resulted in roll box doors 36 that are cumbersome and may require the efforts of two or more individuals to open.
The actual separation of the seed from lint takes place in the roll box 25 of the gin saw stand 10 . In the prior art gin saw stand 10 illustrated in FIG. 1 , a set of ribs, referred to as the ginning ribs 26 , are located in the spaces between the blades 13 of the saw 12 at the downstream end of the roll box 25 , and extend from a position above the periphery 15 of the saw 12 downward through the spaces between the blades 13 to near or below the bottom of the saw 12 . Cotton fibers in the roll box 25 are caught by the teeth of the first saw and passed toward the ginning ribs 26 . As the teeth of the saw 12 pass between the ginning ribs 26 , they pull the lint from the seeds, which are too large to pass between adjacent ribs 26 . The seed-free lint proceeds past the ginning ribs 26 where it is removed from the teeth of the blades 13 by the faster moving brushes of the doffing brush 27 and passed out of the gin stand 10 through the doffing outlet 29 for transferral to the lint cotton cleaners and/or the battery condenser and bailing press depending upon the design of the installation.
As the seeds in the seed roll become substantially free of lint or in a substantially completely “ginned” state, they are of appropriate size and character to pass gravitationally downward adjacent the ginning ribs 26 between the saw blades 13 through the seed discharge shaft 31 and into a seed collection area 32 in the front lower portion of the gin saw stand 10 , to be picked up by the usual seed discharge screw conveyor 33 and delivered to the discharge point (not shown). Lint-free seeds are not held firmly within the surface of the seed roll and often escape the seed roll along the relatively sharp curve or bulge in the seed roll that is formed at the bottom of the seed roll over the seed discharge shaft 31 immediately prior to being pulled upward by the periphery 15 of the saw 12 . The seed discharge shaft 31 is defined by the space between the ginning ribs 26 and the closest, lower breast-side edge 45 of the roll box 25 . Note, however, that when the breast 18 is in the closed position, the blades 13 extend through the ginning ribs 26 and into the seed discharge shaft 31 .
In contrast to the substantially lint-free seeds, seeds which retain cotton fibers thereon generally remain on the surface of the mass of seeds and seed cotton (the seed roll) in the roll box 25 , awaiting to be caught by the saw 12 and repeat the ginning operation.
In some models of gin saw stands, one or more rotating agitators 75 transversely spanning the gin saw stand 10 substantially parallel to the axis 14 of the saw 12 and having a serrated outer edge or periphery 76 , have been placed in the roll box 25 to assist the gin saw 12 in turning the roll of material within the roll box 25 . Typically, such agitators 75 comprise a plurality of discs 77 about the agitator axis 78 , said discs 77 having serrated teeth about the periphery 76 and being canted at an angle relative to the gin saw blades 13 to cause some side to side action within the seed roll. The agitator 75 spins in a direction counter to the direction of the spinning saw 12 . The agitator 75 is typically not located in the exact center of the roll box cavity 25 , but is somewhat offset, and its periphery 76 is closer to the periphery 15 of the saw 12 than to the other surfaces defining the roll box 25 . In some designs (not shown in FIG. 1 ), the agitator axis 78 further comprises or may be replaced by a perforated tube containing an auger which provides an additional path for seed to leave the seed roll.
The gin stand 10 typically comprises a casing or housing comprising a main gin frame 17 supporting the gin saw cylinder 12 and doffing brush 27 , and a separable front, forwardly movable breast 18 including inlet cotton chute 11 and the supports for ginning ribs 26 , picker roller 21 , roll box door member 36 , and (if any) agitator 75 , permitting the breast structure 18 to be drawn away from the main gin frame 17 . The breast 18 is typically attached to the main gin frame 17 in such a manner that it may be pulled away from the frame 17 . In the prior art gin saw stand 10 shown in FIG. 1 , the breast 18 is moved away from the frame 17 substantially laterally along the surface of an integrated rail or track 49 on opposing sides of the frame 17 by powered gears or a pneumatic cylinder (not shown in FIG. 1 ) or other common means. Another typical configuration is shown in FIG. 2 wherein the breast 18 is attached to the frame 17 at a pivot point 19 located near the front bottom of the main gin frame 17 so that the breast 18 may be tilted away from the main gin frame 17 , thereby creating greater space between the breast 18 and the main gin frame 17 at the top of the breast 18 than at the lower regions. The breast 18 is typically attached to the main gin frame 17 at the top by a pneumatic or hydraulic cylinder 47 to power the movement of the breast between a fully-open, non-ginning position and closed, ginning position.
Moving or tilting the breast 18 or otherwise withdrawing it from the main gin frame 17 may be used as a method of interrupting the ginning process instead of stopping the saw 12 from turning. As the breast 18 is withdrawn to a fully-open position, the ginning ribs 26 move even with, or preferably beyond or outside the periphery 15 of the saw 12 , thereby preventing the saw cylinder 12 from removing lint from the seed roll 25 . This is important because it is much more efficient to simply move the breast 18 away from the main gin frame 17 than to stop the relatively massive saw cylinder 12 from spinning, then having to bring it back up to speed when the ginning process is to be re-started. As a practical matter, it is impossible to restart a motionless saw 12 with a full seed roll if the breast 18 is in the ginning position. The saws will encounter so much resistance, that the motor cannot start without over loading the motor starter.
Over the years, the capacities of gin saws 12 have increased, with the stands becoming wider and wider and with higher density seed rolls. As capacities have increased, the width of the seed discharge shaft 31 between the ginning ribs 26 and the lower, breast-side edge 45 of the roll box 25 immediately above the picker roller 21 has also increased to allow more cotton into the roll box and more ginned seed out. A drawback to this approach is that when the breast 18 is moved away from the main gin frame 17 , an relatively larger open gap is created between the lower, breast-side edge 45 of the roll box 25 and the ginning ribs 26 as the blades 13 of the saw 12 are withdrawn from between the ginning ribs 26 . When in operation, this gap is occupied by the portion of the saw blades 13 that extends through the ginning ribs 26 and the spin of the saw blades 13 provides an upward current in the mass of seeds and seed cotton in the roll box such that there is little likelihood that seed cotton will fall down the seed discharge shaft 31 . However, as progressive models of saw stands have moved the lower, breast-side edge 45 of the roll box 25 higher and higher above the picker roller 21 to allow for greater cotton flow, the width of the open gap created when the breast 18 is opened has also increased because as seen in FIG. 1 , the ginning ribs 26 typically have a curvature that mirrors an arc of the periphery 15 of the circular saw blades 13 . Therefore, the higher the bottom edge 45 of the seed box 25 is positioned relative to the periphery 15 of the saw 12 , the further the ginning ribs 26 curve away from the bottom edge 45 at that same relative height.
The larger gaps created when the breast 18 is opened combined with the bigger and more dense seed rolls in current gin saw stands, has led to an increase in the occurrence of seed roll breakage, with parts of the roll, and sometimes even the entire seed roll, including un-ginned seeds with usable cotton, breaking off and falling into the seed discharge shaft 31 when the breast 18 is opened because it is no longer supported by the saw 12 or the lower edge 45 of roll box 25 and/or seed vanes 40 (if any). Obviously, the loss of un-ginned cotton down the seed discharge shaft 31 is undesirable in that it is either wasted or reclaiming it requires a separate operation, resulting in lower productivity and higher expense.
Efforts have been made in the past to manipulate the shape of the roll box for the purpose of accelerating the removal of fully ginned seed from the seed roll. An example is shown in U.S. Pat. Reg. No. 4,974,294 issued to Vandergriff entitled Cotton Gin Seed Vanes and Seed Roll Box, wherein a set of spaced-apart vanes are attached to an adjustable finger shaft thereby allowing for the increased width of the seed passage which aids in increasing the rate of discharge of ginned seeds. The vanes extend from the finger shaft mounted across the breast below the bottom edge of a flat or planar surface of the roll box. The vanes extend from the breast into the seed passage when the breast is closed for operation to prevent the seed roll from sagging too deeply into the seed passage and to purposefully slice into the seed roll with the intent of rupturing the lint-covered surface of the seed roll to more easily allow ginned seeds from the interior of the seed roll to escape. The vanes are spaced apart on the finger shaft to allow ginned seed to fall between them down through the seed passage.
A thorough description of a variety of commercially available gin saw stands and their operation is provided by Anthony and Mayfield (ed.), Cotton Ginner's Handbook, Agricultural Handbook No. 503, United States Department of Agriculture, Agricultural Research Service, Washington, D.C., 1994, the contents of which are incorporated in their entirety by reference herein.
SUMMARY OF THE INVENTION
The present invention relates to a novel gin saw stand having a roll box, the shape of which may be adjusted during operation of the gin saw. Adjustment is possible through movement of one or more members making up one or more segments of the roll box surface. Specifically, the present invention provides a power operated roll box door that may be moved and stopped at any point between fully-opened and fully-closed positions. The roll box door may be adjusted manually or may be operatively connected to a powered means for movement. The present invention also proves a seed roll retaining member that many be adjusted during operation of the gin saw to re-shape the roll box. The seed roll retaining member may be adjusted manually or may be operatively connected to a powered means for movement.
The seed roll retaining member is further biased to extend to its fullest extent towards the cylindrical saw when the breast of the gin saw stand is opened to provide support for and substantially retain the seed roll in place above the saw. When closed, the seed roll retaining member is not extendable to the maximum extent, and is only capable of such extension when the breast is opened.
It is therefore an object of the present invention to provide an improved gin saw stand having a roll box with one or more surfaces that are adjustable to reconfigure the size of the roll box during ginning operations.
It is another object of the present invention to provide a gin saw stand having a powered roll box door positionable anywhere between its fully-opened and fully-closed positions.
A further object of the present invention is to provide a gin saw stand having a roll box retainer member which is adjustable during ginning operations to modify the shape of the roll box and which automatically extends even further into the seed discharge shaft to provide support for the seed roll when the breast is opened.
Another object of the present invention is to provide a gin saw stand having a cam shaft assembly allowing for fine adjustment of the seed roll retaining member to enhance the performance of the gin saw by adjusting the width of the seed discharge shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a side cross section view of a conventional gin saw stand of the prior art.
FIG. 2 is a side cross section view of the gin saw stand of the present invention.
FIG. 3 is a side cross section of a portion of the breast and saw of the present invention with the breast in the ginning or closed position illustrating the range of motion of the seed roll retaining member utilizing the cam and cam shaft mechanism.
FIG. 4 is a side cross section of a portion of the breast and saw of a less preferred embodiment of the present invention with the breast in the ginning or closed position illustrating the full range of motion of the seed roll retaining member utilizing the integral shaft of the seed roll retaining member.
FIG. 5 is a side cross section of a portion of the breast and saw of the present invention with the breast in the open position illustrating the range of motion of the seed roll retaining member utilizing the cam and cam shaft mechanism.
FIG. 6 is a side cross section of a portion of the breast and saw of the present invention with the breast in the open position illustrating the range of motion of the seed roll retaining member utilizing the integral shaft of the seed roll retaining member.
FIG. 7 is a partial right side front view of the breast of the present invention.
FIG. 8 is a right side view of the breast of the present invention.
FIG. 9 is a left side view of the breast of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 2 , the gin saw stand of the present invention 50 comprises an inlet cotton chute 11 wherein the seed cotton is deposited leading to a picker roller 21 which assists in guiding the seed cotton against the periphery 15 of the circular blades 13 of cylindrical saw 12 . The inlet cotton chute 11 is defined within the breast 18 of the gin saw stand 50 by rear and front panels 56 and 57 , respectively, transversely spanning the breast 18 and first 54 and second breast side panels 55 (shown in FIGS. 8 and 9 ) of the breast 18 .
The picker roller 21 throws the seed cotton in the inlet cotton chute 11 against the outer periphery 15 or teeth of the saw 12 which draws the locks of cotton upward through the seed discharge shaft 31 and into the lower portion of the roll box 25 positioned above the axis 14 of the saw 12 where the seeds with attached cotton accumulate into the seed roll. In the present invention, the seed discharge shaft 31 is defined by the space or shortest distance between the ginning ribs 26 and the curved bottom elbow 61 of the seed roll retaining member 60 . As illustrated in FIG. 2 , when the breast 18 is in the closed position, as it is during ginning operations, the blades 13 of the saw 12 extend through the ginning ribs 26 and into the seed discharge shaft 31 .
As previously discussed, seed cotton remains circulating within the roll box 25 until the ginning action of the saw 12 and ginning ribs 26 remove substantially all of the cotton lint from the seeds. The lint is pulled from the seeds through the ginning ribs 26 where it is removed from the teeth of the saws by the doffing brush 27 and passes out of the gin stand 50 through the doffing outlet 29 . Contemporaneously, as the seeds in the seed roll become substantially free of lint, they are no longer held within the surface of the seed roll and may fall out of the bottom of the seed roll, passing gravitationally through the seed discharge shaft 31 and into a seed collection area 32 in the front lower portion of the gin saw stand 50 .
As in the prior art, the roll box cavity 25 of the present invention is of a somewhat distorted cylindrical configuration, however, unlike in prior art gin saw stands 10 , one or a plurality of the plurality of exposed, inwardly facing surfaces that shape the roll box cavity 25 are adapted to be moved to re-shape the roll box cavity 25 , and thus the seed roll formed within it, while the gin saw stand 50 is actively ginning the seed cotton of the seed roll. In a presently preferred embodiment, the roll box cavity 25 is defined by a plurality of exposed, inwardly facing (relative to the roll box) surfaces, namely, the upper portions 26 a of the ginning ribs 26 , the inner surface member 68 of upper rib support 34 , the concavely curved inner surface 64 of roll box door member 63 , one or more upper breast sheet members 66 and the inner surface 59 of the proximal end 58 of the seed roll retaining member 60 . In the roll box 25 of the present invention 50 , a gap 35 exists between the outer end 71 of the door member 63 and the upper sheet member 66 of the breast 18 .
Door member 63 is hinged to the breast 18 at one or more pivot points, such as a transversely spanning shaft or axis 65 . Door member 63 rotates about the pivot point between a fully-closed position and a fully-opened position. Means for moving and holding the door member at any position between the fully-closed and fully-opened positions is provided, such as pneumatic door cylinder 72 attached to the shaft 65 on the outside 54 of breast 18 . Alternate means for moving the door, such as a hydraulic piston or powered gears or other conventional motors are within the contemplation of this invention. Preferably, the door member 63 is capable of movement through an arc of between about 40 to about 60 degrees between the fully-opened and fully-closed positions, though greater ranges of motion up to about 180 degrees are potentially possible. When in the fully-closed position as illustrated in FIG. 2 , door member 63 rests against the upper end 86 of upper rib support 34 or the inner surface member 68 of rib support 34 .
The seed roll retaining member 60 transversely spans the breast 18 of the gin saw stand 50 substantially parallel to the axis 14 of the saw 12 . The seed roll retaining member 60 is a substantially continuous surface or sheet transversing the breast 18 without perforations, gaps or breaks, and is typically formed of sheet metal, though it may be formed of any suitable substantially rigid material. A first end of the proximal end 58 of the seed roll retaining member 60 is pivotably attached to the breast 18 at one or more pivot points such as transversely spanning seed roll retaining member axis 88 (also referred to herein as the integral shaft). The pivot point 88 is positioned immediately below the lower end 67 of breast sheet member 66 such that the inner surface 59 of the breast sheet member 66 and the inner surface of the proximal end 58 of the seed roll retaining member 60 form a relatively continuous surface of roll box 25 .
Seed roll retaining member 60 further comprises an elbow end 61 , preferably rounded, at the opposing second end of the proximal end 58 opposite the pivot point 88 , forming an angle between the proximal end 58 and the distal end 62 . The distal end 62 is angled relative to the proximal end 58 such that it remains in slidable contact with the lower end 52 of rear panel 57 of breast 18 , preferably the rear surface of the lower end 52 so that there is a relatively smooth transition between the lower end 52 and the distal end 62 of the seed roll retaining member 60 . Maintaining contact between the seed roll retaining member 60 and the lower end 52 of the rear panel 57 of the cotton inlet chute 11 at all times, regardless of whether the seed roll retaining member 60 is in the fully-extended or fully-retracted position or anywhere in between is important to present a continuous surface that blocks seed cotton from being thrown up behind the seed roll retaining member 60 when it is extended and thereby preventing the seed cotton from becoming trapped under the seed roll retaining member 60 and potentially clogging or inhibiting the free rotation of the seed roll retaining member 60 during operation of the gin.
In the preferred embodiment of the present invention 50 , the proximal end 58 and distal end 62 of the seed roll retaining member 60 are spaced-apart members rather than opposite sides of a solid member to reduce overall weight. One or more substantially triangular or pie-shaped supports 92 are spaced along the length of the seed roll retaining member 60 between the proximal end 58 and distal end 62 to maintain the shape of the seed roll retaining member 60 by keeping the proximal end 58 and distal end 62 separated. An opposing pair of outermost supports 92 are positioned flush with the ends of the seed roll retaining member 60 which are, in turn, substantially flush with the sides 54 , 55 of the breast 18 . In a preferred embodiment, each support 92 has a chamfer 83 or blunted point proximate to where it fits into the elbow 61 to avoid the necessity of meeting fine tolerances when assembling the seed roll retaining member 60 .
In an alternate embodiment not shown in FIG. 2 , the seed roll retaining member 60 could be formed as a solid piece with the outward surface 59 of proximal end 58 and distal end 62 being merely the different sides of a solid member. However, based on currently used materials, a solid seed roll retaining member 60 would be unnecessarily heavy and not practicable. Similarly, another alternative not illustrated is to form the seed roll retaining member 60 as a substantially triangular tube.
As illustrated in FIG. 4 , the seed roll retaining member 60 is rotatably attached to the axis 88 so that it may rotate between a first, fully-retracted position (illustrated in solid lines) and a second, fully-extended position (illustrated in dashed lines) through an arc (α) of between about 20 degrees to about 40 degrees.
As illustrated in FIG. 9 , means for moving and holding the seed roll retaining member 60 at any position between the fully-retracted and fully-extended positions is provided, such as retainer pneumatic cylinder 73 linked to the integral shaft 88 , such as by lever 85 . Retainer pneumatic cylinder 73 is preferably a fairly small bore cylinder and its normal state is retracted, thereby tending to keep the seed roll retaining member 60 in its fully-retracted position and its internal supports 92 engaged with the cams 91 of the cam shaft assembly 89 .
As shown in FIG. 2 , the gin saw stand 50 further comprises a cam shaft assembly 89 for moving the seed roll retaining member 60 , particularly during ginning operations. The cam shaft assembly 89 comprises a cam shaft 90 transversing the breast 18 with an axis parallel to the integral shaft 88 of the seed roll retaining member 60 . One or more lobed or oblong cams 91 are carried upon the cam shaft 90 with each cam 91 normally in sliding contact with the seed roll retaining member 60 , preferably with an associated support 92 of the seed roll retaining member 60 . Turning the cam shaft 90 causes the lobe of the cam 91 to push upon the associated support 92 of the seed roll retaining member 60 , thereby moving the seed roll retaining member 60 between a normal fully-retracted position and a partially-extended position (illustrated in dashed lines in FIG. 3 ).
As best illustrated in FIGS. 7 and 8 , a means for moving the seed roll retaining member 60 via the cam shaft assembly 89 is provided, such as cam shaft lever 96 operatively attached to the cam shaft 90 and extending through a detented slot 97 in the front panel 56 of breast 18 . The means for moving the cam shaft assembly may be operated manually or by connection to some other power source such as a motor or pneumatic cylinder (not shown). In a preferred embodiment, lever 96 may be manually moved along the length of the slot 97 from a first end 98 to opposing second end 99 and stopped and held in each detention 95 of the slot 97 . When the lever 96 is positioned at one end 98 of the slot 97 , the seed roll retaining member 60 is positioned in the corresponding fully-retracted position, and when the cam shaft lever 96 is positioned at the other end 99 , the seed roll retaining member 60 is positioned in the corresponding partially-extended position. Catching the lever 96 in detensions 95 along the slot 97 positions the seed roll retaining member 60 at corresponding positions between the fully-retracted and the partially-extended positions. Preferably, the cam shaft lever 96 cannot be used to position the seed roll retaining member 60 in the fully-extended position, the limit of its extension by means of the lever 96 being the partially-extended position intermediate the fully-retracted position and fully extended position.
As illustrated in FIG. 3 , the seed roll retaining member 60 may be moved via the cam shaft assembly through an arc Ω of between about 5 degrees to about 10 degrees. The magnitude of the adjustment may be changed by increasing or decreasing the size of the lobe of the supports 92 and by limiting or extending the range of motion of the cam shaft lever 96 within the slot 97 or a combination of both. Alternate means for moving the cam shaft assembly and thereby the seed roll retaining member 60 , such as a hydraulic piston or powered gears or other conventional motors are also within the contemplation of this invention.
In an alternative embodiment, the function served by cam shaft assembly could be accomplished by moving the seed roll retaining member 60 during ginning operations using pneumatic cylinder 73 attached to the integral shaft 88 . The cylinder 73 may be equipped with a linear positioning device providing exact piston location within the cylinder and a control panel on the gin 50 configured to provide an adjustment range similar to the range available using the manual lever 96 . Another potential method of moving the seed roll retaining member 60 during ginning operations would be the use of a ball screw actuator equipped with a rotary encoder. Other means common in the art are also within the contemplation of this invention, but are not as favored as the cam shaft assembly 89 due to increased costs.
In one preferred embodiment, the seed roll retaining member 60 is configured such that it can only be moved into the fully-extended position by the retainer pneumatic cylinder 73 but not cam shaft assembly. Allowing the positioning of the seed roll retaining member 60 into the fully-extended position using the manual lever 96 of the cam shaft assembly or other means may be potentially disadvantageous because, as shown in FIG. 4 , with the breast 18 in the operative, ginning position, fully extending the seed roll retaining member 60 would substantially close off or restrict the unobstructed portion of the seed discharge shaft 31 not occupied by the blades 13 of the saw 12 , said open span being referred to herein as the open shaft span 93 . Substantially restricting or closing off the open shaft span 93 of the seed discharge shaft 31 also substantially closes off or restricts the path for new seed cotton as it is pulled upward by the periphery 15 of the saw 12 into the roll box 25 . If the width of the open shaft span 93 is too restricted or made too small, seed cotton in the gin 50 will tend to choke or clog up at that point, leading to extremely undesirable results and, potentially, failure of the gin 50 . Accordingly, the cam shaft assembly is preferably mechanically restricted by an appropriate physical limiting structure so that it cannot be used to move the seed roll retaining member to the fully-extended position when the breast 18 is closed, such as by limiting the size of the lobes of the cams 91 or restricting the movement of the cam shaft lever 96 . Similarly, the pneumatic cylinder 73 cannot be operated to fully extend the seed roll retaining member 60 when the breast 18 is closed. Only contemporaneously with or after the flow of seed cotton into the inlet cotton chute 11 has been cut off, which will result in substantially all of the seed cotton in the chute 11 being drawn up into the roll box 25 within a matter of a few seconds, may the breast 18 begin the process of being drawn away from the saw cylinder 12 by the pneumatic breast cylinder 47 .
As best shown in FIG. 3 , the present invention 50 , the seed discharge shaft 31 is defined by the distance (y) between the ginning ribs 26 and the elbow 61 of the seed roll retaining member 60 , and the open shaft span 93 is defined by the distance (z) between the elbow 61 and the periphery 15 of the saw cylinder 12 . The ability to manipulate or vary the width of these distances, both when the breast 18 is opened and when it is closed, is an essential goal of the present invention because even relatively slight adjustments to these distances can generate tremendous performance enhancement in the operation of the gin 50 and substantially reduce the loss of unginned seed cotton when the breast 18 is opened. In particular, the ability to extend the seed roll retaining member 60 to within a few inches of the ginning ribs 26 when the breast 18 is open is a substantial improvement not accomplished in the prior art.
When the breast 18 is closed and the seed roll retaining member 60 is positioned in the fully-retracted position, the width (y) of the seed discharge shaft 31 is about 3.5 inches (about 8.9 cm) and the width (z) of the open shaft span 93 is about 1.5 inches (about 3.8 cm). When the breast 18 is closed, the distance (z) of primary importance is the open shaft span 93 , and the width (y) of the seed discharge shaft 31 is of only secondary importance because in different models of gin saw stands, the distance the saw blades 13 extend past the ginning ribs at this closest point my vary. Variations in the shape or contour of the ginning ribs 26 proximate to this point may also result in differences in the width (y) of the seed discharge shaft 31 , but the operational improvements result from the ability to vary the width (z) of the open shaft span 93 .
When the breast 18 is closed and the seed roll retaining member 60 is extended to the greatest extent possible by manual adjustment with the cam shaft lever 96 (i.e., an intermediate partially-extended position) as shown in FIG. 3 in dashed lines, the width (z′) of the open shaft span 93 is about 15/16 inches (about 2.4 cm) and the width (y′) of the seed discharge shaft 31 is about 3 inches (about 7.6 cm).
FIG. 4 illustrates a non-preferred embodiment in which the seed roll retaining member 60 is configured to extend to its fully-extended position when the breast 18 is closed. In such a configuration, the width (z′) of the open shaft span 93 is about 3/16 inches (about 0.5 cm) and the width (y′) of the seed discharge shaft 31 is about 2 inches (about 5.1 cm). However, as previously discussed, reducing these widths to such an extent tends to result in clogs and blockage of the open shaft span 93 and seed discharge shaft 31 . Even in such a configuration, when the breast 18 is closed, meaning the blades 13 of saw 12 are extended to the fullest extent between the ginning ribs 26 , the proximal end 58 must not be of such a length that the elbow 61 would come into contact with the periphery 15 of the blades 13 . In other words, the elbow 61 can be configured to pass extremely closely over the surface of the saw 12 , but actual contact between the two should be physically impossible to avoid damage to the seed roll retaining member 60 and blades 13 .
Preferably, the means for moving the seed roll retaining member 60 via the integral shaft 88 is configured to preclude it from reaching the fully-extended position except when the breast 18 is opened, and then preferably only when the breast 18 is also opened to its fullest extent. In a preferred embodiment, the seed roll retaining member 60 is biased to automatically extend to the fully-extended position when the breast 18 is opened, thereby automatically shortening the distance between the ginning ribs 26 and elbow 61 (i.e., the seed discharge shaft 31 ) to the fullest extent possible, and thereby providing additional support for the seed roll along the proximal end 58 of the seed roll retaining member 60 and substantially reducing the likelihood that significant portions of the seed roll within the roll box 25 will break away and fall through the seed discharge shaft 31 and into the seed collection area 32 .
Biasing of the seed roll retaining member 60 to the fully-extended position when the breast 18 opens may be accomplished in many ways familiar in the art, such as simply programming pneumatic cylinder 73 to actuate in coordination with the actuation of the pneumatic cylinder 47 that moves the breast 18 . Other means for mechanically biasing the seed roll retaining member 60 are within the contemplation of this invention, such as connecting a lever on roll retainer member 60 to a mechanical linkage actuated by the motion of the breast 18 drawing away from the saw 12 . Alternately, and not by way of limitation, the retainer cylinder 73 may be linked or otherwise programmed to operate to extend the seed roll retaining member 60 to the fully-extended position only in tandem with the opening of the breast 18 by the breast cylinder 47 .
When the breast 18 is open as shown in FIG. 5 , the width (y) of the seed discharge shaft 31 is the tolerance of primary importance because the periphery 15 of the saw cylinder 12 is substantially withdrawn from between the ginning ribs 26 thereby completely clearing or removing any impediments from the seed discharge shaft 31 . As a practical matter, it will be apparent that when the breast 18 is opened, the width (y) of the seed discharge shaft 31 and the width (z) of the open shaft span 93 are substantially identical. As stated above, the open shaft span 93 is defined as the portion of the seed discharge shaft 31 not occupied by the blades 13 of the saw 12 . When the breast 18 is open, no material portion of the seed discharge shaft 31 is occupied by the blades 13 .
As best illustrated in FIG. 4 , when the breast 18 is in the fully-extended position, the internal supports 92 of the seed roll retaining member 60 are drawn away from contact with the associated cams 91 , even if the cam shaft 90 is turned so that the lobe of the cams 91 would otherwise be extending the seed roll retaining member 60 to an intermediate position (as shown in dashed lines in FIG. 3 ). When the pneumatic cylinder 73 attempts to return the seed roll retaining member 60 to its normal fully-retracted state, as it is withdrawn, the supports 92 would come back into contact with the extended cams 91 , and thus the seed roll retaining member 60 would remain in the position to which the cam shaft assembly is set, rather than returning to the fully-retracted state. Thus, during operation, once a desirable setting of the width (y)of the seed discharge shaft 31 has been achieved using the cam shaft assembly 89 to move the seed roll retaining member 60 , the breast 18 can be opened, which results in the automatic movement of the seed roll retaining member 60 to its fully-extended position, then the breast 18 can be closed again and the seed roll retaining member 60 will assume the position last set by the cam shaft assembly 89 and does not require additional adjustment.
As shown in FIG. 6 , when the breast 18 is opened and the seed roll retaining member 60 is in the fully-extended position (illustrated in dashed lines), the proximal end 58 has a length configured to result in a seed discharge shaft 31 having a width (y′) of about 2.0 inches (about 5.1 cm) or less and the distance (z′) between the elbow 61 and the periphery 15 of the saw 12 is about 2.5 inches (about 6.4 cm) or greater. Fully extending the seed roll retaining member 60 when the breast 18 is open serves the function of supporting the seed roll and preventing it, or portions thereof, from falling through the seed discharge shaft 31 . This supportive function is not materially served when the seed discharge shaft 31 is greater than about 4¾ inches (about 12 cm) in width (y′); no meaningful support is provided when the seed discharge shaft 31 is more than about 6 inches (about 15 cm) in width (y′), with the seed roll or substantial parts thereof being lost the majority of the time at this width. When the breast 18 is opened and the seed roll retaining member 60 is in the fully-retracted position (illustrated in solid lines in FIG. 6 ), the width (y) of the seed discharge shaft 31 is about 3.5 inches (about 8.9 cm) and the distance (z) between the elbow 61 and the periphery 15 of the saw 12 is about 4.0 inches (about 10.2 cm) or greater.
As illustrated in FIG. 5 , when the breast 18 is opened and the seed roll retaining member 60 is extended to the greatest extent possible by manual adjustment with the lever 96 (illustrated in dashed lines), i.e., the partially-extended position, the width (y′) of the seed discharge shaft 31 is about 3.0 inches (about 7.6 cm) and the distance (z′) between the elbow 61 and the periphery 15 of the saw 12 is about 3 7/16 inches (about 8.7 cm) or greater.
Although this invention has been disclosed and described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. | A saw type gin stand for separating cotton lint from seed cotton in which the improvement comprises one or more of the inwardly facing surfaces of the roll box being movably adapted to re-shape the roll box. Specifically the inner surface of the roll box door member and a seed roll retaining member are adjustable during operation of the gin to re-shape the shape of the gin to optimize performance and, when the breast is opened, to retain the seed roll within the roll box and prevent pieces of the seed roll from breaking off of the roll. | 3 |
RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 14/331,147, filed Jul. 14, 2014, entitled “Phototherapeutic Near IR Fluorescent Ophthalmic Lenses and Light Filters” which claims the benefit under 35 U.S.C. 119(e) of the U.S. provisional application No. 61/957,818 filed on Jul. 12, 2013 and of the U.S. provisional application No. 61/957,826 filed on Jul. 12, 2013.
FIELD OF THE INVENTION
[0002] The present invention is directed to ophthalmic lenses and light filters containing fluorescent compounds that absorb light in the UV and visible region of wavelengths and that have fluorescence emission in selected wavelength regions of the red and near infrared—in order to enhance phototherapy for the human eye when it is exposed to sunlight and artificial lighting.
DESCRIPTION OF THE RELATED ART
[0003] Prior art has described light filtering agents for sunscreens that filter primarily UV light (U.S. Pat. Nos. 4,889,947; U.S. Pat. Nos. 4,950,467; 8,278,459). A pending application (Dyan and Gallas) was filed 3 March entitled, ‘Compound, Composition, and Method for Protecting Skin from High Energy Visible Light’ 61/217,207 Filed May 28, 2009, “Compound, Composition, and Method for Protecting Skin from High Energy Visible Light,” and describes the use of melanin with enhance absorption of HEV light and enhanced transmission of red light for skin care applications.
[0004] A pending application (Gallas and Simmons, Ser. No. 12,807,656) describes the use of melanin as an ideal light filter that optimizes protection, vision and NIR-based therapy as indicated by its transmission spectrum shown in FIG. 1 . Specifically, the applicants (Gallas and Simmons, application Ser. No. 12/807,656) proposed to transmit 100% of the light between 700 nm and 1200 nm and, furthermore, to use anti-reflective coatings to increase the transmission over the wavelength range 700 nm to 1200 nm.
[0005] In each of the above cases, the light filtering agents proposed reduce the risk of damage due to photochemistry of tissue that is associated with the higher energy photons—400 nm to 500 nm; and they transmit red and near infrared light that is believed to be therapeutic to tissue. And whatever light that is absorbed by the protective light filters is converted into heat through radiationless transitions from the excited states—rather than through fluorescence, for example.
[0006] For the purposes of describing this invention it is noted that: a) the terrestrial electromagnetic radiation from the sun (shown in FIG. 1 ) spans a region of wavelengths that includes the UV, the HEV (high energy visible), visible light and the near IR (near infrared); direct sunlight that reaches the human eye contains solar energy composed of 6.8% ultraviolet light, 38.9% visible light, and 54.3% infrared radiation. b) it is well-known that exposure to the UV region of light increases the risks of damage to the skin and to the lens of the eye; c) more recently, the HEV region of wavelengths have been associated with an increased risk for macular degeneration and also damage to the skin; d) the visible region is what is used by humans to get around; and e) still more recently, the near IR (NIR) part of the electromagnetic spectrum of wavelengths is believed to result in cellular repair or therapy; and finally, f) a molecular mechanism has been proposed for this repair that involves absorption of NIR light by cytochrome-C found in every cell ( FIG. 2 ). The process is seen to energize the cells and initiate a therapeutic response of repair to the tissue; and the action spectrum for cytochrome-C spans the wavelength range continuously from 700 nm to 1200 nm.
BRIEF SUMMARY OF THE INVENTION
[0007] The objects of this invention are: to increase the intensity of the red and near IR photons from sunlight that reach the cornea, lens and retina of the human eye—beyond what is directly emitted by sunlight—by the use of appropriate fluorescent compounds.
[0000] The objects of this invention are also to specify the wavelength regions for light absorption and emission by the fluorescent compounds that are appropriate for photo-therapy for the eye; the objects of this invention are also to identify and incorporate fluorescent compounds having the appropriate absorption and emission spectra; and finally, the objects of this invention are to incorporate the above fluorescent compounds into ophthalmic lenses that preserve the optical qualities for phototherapy of the eye described above.
[0008] The additives of this invention will selectively absorb UV, HEV and visible light and convert the excited state energy associated with this absorption into fluorescence. And furthermore, the fluorescence emission should span the wavelength range primarily from 700 nm to 1200 nm—the wavelength region of absorption by cytochrome-C ( FIGS. 3 and 4 )—but to also include the region from 600 nm to 1200 nm. Phototherapy is thereby enhanced in this invention over all prior art because excited state energy created from the absorption of light over the region between 300 nm and 700 nm, and that would otherwise have been dissipated as heat—as in the case of prior art—is transformed, instead, into NIR light that is absorbed by cytochrome-C. This NIR fluorescence is separate, distinct from, and over and above the NIR component of sunlight that is simply transmitted by the chromophores or fluorophores (as disclosed, for example in the patent applications by Gallas and Dyan cited above) Definitions.
[0009] UV. UV light is the electromagnetic radiation having wavelengths that span the region of about 200 nm to 400 nm. Very little sunlight has a components in the region between 200 nm and 300 nm.
[0010] HEV. HEV light is the high energy visible region of the electromagnetic spectrum of wavelengths—between 400 nm and 480 nm.
[0011] PT Light Filters with NIR Luminescent Materials means Phototherapeutic Light Filters with Near Infrared Luminescent Materials.
[0012] Luminescent materials means materials that fluoresce or phosphoresce.
[0013] Melanin is the pigment as defined in U.S. Pat. No. 5,112,883
[0014] Ocular Lens Pigment is the pigment as defined in U.S. Pat. No. 6,825,975
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 —The solar intensity as a function of wavelength. Sunlight that reaches the human skin contains solar energy composed of 6.8% ultraviolet light, 38.9% visible light, and 54.3% infrared radiation.
[0016] FIG. 2 —Proposed action spectra for cytochrome-C. Absorption spans the red to near IR range of wavelengths.
[0017] FIG. 3 . Absorption and Emission spectra of a commercially available fluorophore that absorbs light in the visible part of the spectrum and emits in a range if near IR wavelengths that overlap the action spectrum of cytochrome C of FIG. 2 .
[0018] FIG. 4 Emission spectrum measured from a suspension of single-walled carbon nanotubes in aqueous media using laser excitation at 658 nm. (Figure courtesy of Applied NanoFluorescence, LLC)
[0019] FIG. 5 . Absorption and Emission spectra of a commercially available fluorophore (Life Technologies) that absorbs light in the visible part of the spectrum and emits in a range if near IR wavelengths that overlap the action spectrum of cytochrome C of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] Luminescence is a physical process whereby an electron is excited by a photon with de-excitation occurring almost spontaneously, and whereby emission from a luminescent substance ceases when the exciting source is removed. In fluorescent materials, the excited state has the same spin as the ground state. If denotes an excited state of a substance A, then fluorescence consists of the emission of a photon,
[0000] A*→A+hv,
[0021] In phosphorescence, there is a change in electron spin, which results in a longer lifetime of the excited state (second to minutes). It is an essential point of this invention that fluorescence and phosphorescence occur at longer wavelength than the excitation radiation.
[0022] More specifically, if a molecule or compound absorbs UV or HEV (high energy visible) light, then emission can occur at longer-wavelength red light. Furthermore, some specific substances are able to fluoresce selectively in the range of wavelengths from 700 nm to 1200 nm. This range of wavelengths—from 700 nm to 1200 nm—is absorbed by cytochrome C and the process is associated with energizing cells and the repair of human tissue.
[0023] An essential object of this invention is to increase the intensity of the near Infrared (NIR) light that reaches the cornea, lens and retina of the human eye—beyond what is directly emitted by sunlight—by the use of appropriate fluorescent compounds that are incorporated into ophthalmic lenses and other light filters. In this invention, UV and visible light that would otherwise be absorbed and then converted to heat—as in the case of all previous art relating to sunglass lenses and ophthalmic lenses, in general—is absorbed and then, at least partially converted into near infrared fluorescence.
[0024] The objects of this invention are also to: a) specify the wavelength regions for light absorption and emission by the fluorescent compounds that provide as much photo-therapy for the eye—but without otherwise compromising vision, given that fluorescent light is a source of glare; b) identify and incorporate fluorescent compounds having the appropriate absorption and emission spectra according to a); and c) to incorporate the above fluorescent compounds into ophthalmic lenses that preserve the optical qualities for phototherapy of the eye described above.
Preferred Embodiment
[0025] A preferred embodiment for the objects of this invention is to identify materials that: a) selectively absorb UV and visible light; b) also have a high transmission of near IR light; c) the materials of a) and b) fluoresce or luminesce primarily over the region of wavelengths 600 nm to 1200 nm that matches—or falls within—the action spectrum for cytochrome C which has been associated with the repair of human cells; and d) to demonstrate that the preceding materials can be incorporated into ophthalmic lens materials. Thus, the excitation spectrum of the fluorophores should span the region 300 nm to 700 nm, and the fluorescence emission spectrum should be similar in shape to the action spectrum or optical absorption spectrum for cytochrome C and span the region of wavelengths between 600 nm and 1200 nm—or if not similar, fall within the region 600 nm to 1200 nm. In this way, sunlight energy with wavelengths between 300 nm and 700 nm that is absorbed by a light filter such as a sunglass lens or a light filter—that would otherwise convert this light into heat—will, instead, be converted into fluorescence. And this emission of near infrared light that will energize the cells of human tissue resulting in repair or therapy of ocular tissue.
[0026] Normally, light that enters the eye other than what is associated with what is being imaged is considered glare. Thus, an image of some object of interest and which is produced by reflection of sunlight of this object and which enters the eye and carries an image of the object to the retina will be compromised by extraneous light such as fluorescence—the latter being defined as glare.
[0027] Thus, It is an important consideration of this invention that the naturally-occurring benefits of repair that can arise from near IR fluorescence are possible because such fluorescence occurs in a region of wavelengths wherein the eye is not sensitive to such light that would otherwise be considered glare.
[0028] Several inherent factors can mitigate the performance of this invention: The Stokes Shift imposes practical limits on the wavelength differences between peak excitation and peak emission wavelengths. Very large Stokes shifts are reported as nominally 200 nm. This means that most fluorophores in light filters that are excited by light having wavelengths of 500 nm or shorter will not likely emit at wavelengths longer than 700 nm. Then if fluorescent materials are chosen with excitation maxima occurring in the HEV region of wavelength, a significant part of their emission maxima will likely occur in the visible part of the spectrum and this light will be perceived as glare because fluorescence is not associated with any image and so competes with the light carrying the image.
[0029] More accurately, there will be less materials available with Stokes shifts larger than 200 nm that would allow NIR fluorescence to occur if the excitation wavelengths fall within the UV or HEV region of wavelengths. However, some materials can be identified with very large Stokes shifts and can be used as an object of this invention. Furthermore, even if significant fluorescence occurs in the visible region of wavelength, it may not be perceived as significant glare provided that such fluorescence is limited to the red end of the spectrum (650 nm and longer) where the sensitivity of the eye is very low.
[0030] If a ‘perception of significant glare’ can be quantified, then a minimally acceptable level of fluorescence in the visible region can be set as follows: In the case of sunglass lenses, a haze value of approximately 1% or less is considered acceptable for the consumer by the lens industry. In this case, the haze is the result of scatter off of micron-sized particles by the visible part of the sunlight passing through the lens. Fluorescence can roughly be considered in the same light as haze. Thus a fluorescence intensity of approximately 1% of the light that enters the eye could be set as a maximum value to be tolerated. However, the sensitivity of the eye can also be factored into this maximum value as follows
[0000] Haze FI =ΣF λ ×S λ .Δλ/ΣI λ Δλ
[0000] Σ F λ ×S λ ./I
[0000] Where F λ is the fluorescence intensity at a specific wavelength; S λ is the sensitivity of the eye at that wavelength; at a specific wavelength; I λ is the intensity of the light passing through the light filter at that wavelength; and Δλ is the wavelength interval.
[0031] Thus, the haze due to fluorescence—factoring in the overlap between the sensitivity spectrum of the eye and the fluorescence emission spectrum. For example, the eye has very little sensitivity at 650 nm; and still less at 700 nm; and hardly any beyond 750 nm. Thus the sum in the above equation for the haze should run between 600 nm and 750 nm. Beyond 750 nm, any near IR light that is enhanced by the articles of this invention will not contribute to glare; however, another essential aspect of this invention is that it is possible—and useful—to allow some light between 600 nm and 750 nm to be enhanced by the fluorescent compounds envisioned in this invention to because they may contribute significantly to photo-therapy.
[0032] Organic dyes, quantum dots, and single-walled carbon nanotubes (SWNTs), have been employed for in vitro and in vivo biological imaging in the NIR region. SWNTs are a group of one-dimensional (1-D) macromolecular fluorophores, with intrinsic bandgap fluorescence emission between 0.9-1.4 μm upon excitation in the visible or NIR. The large Stokes shift makes SWNTs ideal probes for biological imaging with high contrast and low background. Thus far, SWNTs have been used as in vitro fluorescence tags for cell imaging, ex vivo imaging of tissues and organs, and in vivo imaging of normal organs as well as tumors. An example of the fluorescence of a SWNT is shown in FIG. 4 that could be used to realize the objects of this invention.
[0033] Another object of this invention is to create new materials or modify existing materials to increase the overall fluorescence or quantum yield for emission in the region 700 nm to 1200 nm that also have the properties of a) through c) inclusive of the preceding paragraph.
[0034] Applicant notes there are several ways to cause such a modification: 1) the materials selected can be chemically of physically modified to increase their Stokes shift so that either shorter excitation wavelengths can be achieved for a given emission maxima, or or so that longer emission wavelengths can be achieved for give excitation wavelengths; 2) the quantum efficiency can be increased using standard methods (for example, increasing/decreasing the rigidity of the host medium, etc.)
[0035] The fluorescent molecules or compounds of this invention can also be blended with common ophthalmic lenses in a thermoset lens casting process, or in in injection molding process commonly used to make sunglass lenses. In this way, the UV and HEV components of sunlight (or artificial light) are absorbed by the compound instead of being absorbed by the cornea or retina of the eye.
[0036] This objects of this invention can be realized by: A) selection of existing compounds and molecules that have the light-absorption and luminescence properties described above; or, B) by chemical modification of existing molecules to enhance the absorption and fluorescence to better conform to the properties described above.
[0037] A particular technical challenge of the present invention is the inherently-small Stokes shift (the difference in wavelength or frequency units between positions of the emission and absorption maxima) that is associated with fluorescence. Among the many existing fluorescent molecules and compounds, 100 nm is considered a large Stokes shift. Furthermore, the UV (300 nm to 400 nm) or HEV (400 nm to 500 nm) are both far removed from the near IR (here, 700 nm to 1200 nm). This means that within the UV and visible range of excitation wavelengths, it will be more common to identify a lens filtration system that involves fluorophores with absorption maxima at wavelength nominally greater than 600 nm. This means that most of the candidates for NIR fluorescence will involve emission wavelengths very close to the red end of the visible spectrum. In the case of ophthalmic lens applications, this presents an unwanted potential for glare because omnidirectional fluorescence of visible light competes with light that is carrying an image to the retina. On the other hand, the eye is much less sensitive to red light.
The literature cites other ways to achieve larger Stokes shifts useful for this invention: “A readily accessible new class of near infrared (NIR) molecular probes has been synthesized and evaluated. Specific fluorophores in this unique xanthene based regioisomeric seminaphthofluorone dye series exhibit a combination of desirable characteristics including (i) low molecular weight (339 amu), (ii) aqueous solubility, and (ii) dual excitation and emission from their fluorescent neutral and anionic forms. Importantly, systematic changes in the regiochemistry of benzannulation and the ionizable moieties afford (iv) tunable deep-red to NIR emission from anionic species and (v) enhanced Stokes shifts. Anionic SNAFR-6, exhibiting an unusually large Stokes shift of 200 nm (5,014 cm1) in aqueous buffer, embodies an unprecedented flouorophore that emits NIR fluorescence when excited in the blue/green wavelength region. The successful use of SNAFR-6 in cellular imaging studies demonstrates proof-of-concept that this class of dyes possesses photophysical characteristics that allow their use in practical applications. Notably, each of the new fluorophores described is a minimal template structure for evaluation of their basic spectral properties, which may be further functionalized and optimized yielding concomitant improvements in their photophysical properties.”
[0039] Another NIR fluorescence system can consist of a complex whereby a ‘donor molecule’ absorbs light in the visible region of wavelength and then transfers its excited energy to an acceptor molecule which fluoresces in the NIR region of wavelength—as in the example below:
[0000] “Energy transfer from photoexcited porphyrin molecules to single-walled carbon nanotubes (SWNTs) has been experimentally detected for samples in aqueous Triton X-100 micellar suspensions. Addition of SWNTs to micelle-suspended porphyrin results in strong quenching of porphyrin fluorescence. Measurements of concentration-dependent quenching and spectra suggest that this process arises from formation of ground state non-covalent complexes between porphyrins and SWNTs. Optical excitation of the porphyrin generates characteristic near-IR emission from the SWNTs, indicating efficient energy transfer within the complexes. This energy transfer is deduced to occur through a Dexter-type electron exchange mechanism. Complexation of SWNTs with organic photosensitizers provides a novel way of uniformly exciting a wide range of nanotube structural species in polydisperse samples using only a single excitation wavelength”
Selection and Preparation of the Fluorescent Dyes—Preferred Embodiment.
[0040] The preferred embodiment of this invention is a single substance that has all of the desired properties although to some limited degree. Preferably, the fluorophores will: Will have:
a) an average transmission of 1% or less of the UV light-weighted by the source emission spectrum; b) an average transmission of 5% or less of the HEV light-weighted by the source emission spectrum; c) a fluorescence emission selectively in the near IR between 600 nm and 1200 nm d) A quantum yield—defined as F=[number of photons emitted (600 nm to 1200 nm)/number of photons absorbed (300 nm to 700 nm)] greater than 0.1 e) Factoring in of overlap of sunlight spectrum (S 1 ×starting at 750 nm Σ α λ S λ /ΣS λ . α is the absorption spectrum of cytochrome C;
[0046] So, integrate from I=500 nm to 750 nm gives about 325 w/m2 between 500 nm and 750 nm, or 0.0325 j/sec-cm2.
[0047] So after 100 sec—a reasonable therapy period of time—you have 3.25 j/cm2.—which is just inside the typical range of therapy 2-4 j/cm2.
[0048] So if all of the energy (or a significant part of it) between 500 nm and 750 nm can be converted into near IR instead of heat, then the idea is feasible.
[0049] According to FIG. 3 , for the dye 4-SulfonIR, the principal absorption occurs within the wavelength region of 400 nm to 750 nm; and according to FIG. 4 , the corresponding terrestrial solar intensity in the same region of wavelengths is (750 nm−400 nm)×(˜1.4 W/m2nm)˜490 W/m2.
[0050] So, about ½ of the sun's energy lies between 400 nm and 750 nm (the other half of the sun's energy is distributed over the wavelength regions 300 nm to 400 nm; and 1200 nm to 2500—with the bulk of the energy between 1200 nm and 2500 nm. If 4-SulfoniIR is used as a point of reference, it is possible to approximate the potential of the present invention to create light filters that significantly enhance the throughput of near IR energy by implanting fluorphores into these light filters. Assuming that approximately 75% of the light is absorbed, for example by dyes similar or better than the 4-SulfonIR dye and with a quantum yield of about 75%, then more than 50% of the energy of the visible light could be available as near IR energy for photo-therapy—over and above what might be transmitted in the near IR region, and over and above what might otherwise be absorbed over the region 400 nm to 750 nm and converted into heat instead.
[0051] Assuming a combination of dyes could be identified, it is possible to absorb light in the region between 350 nm and emit throughout the region between 700 nm and 1200 nm and reach higher energies, or fractions of the total near IR energy
Second Embodiment
[0052] A second way to achieve the object of this invention is the preparation of a mixture of fluorophores each having an excitation band (absorption maxima) located at a different wavelength within the UV range (UVA, UVB, UVC) and visible light range (400 nm to 700 nm) and with corresponding emission band in the near IR spanning the range from 700 nm to 1200 nm.
[0053] Generally, hydrophobic fluorophores can be dispersed in organic solvents along with hydrophobic polymers—such as polymethylmethacrylate—after which the solvent is allowed to evaporate and the fluorophore is encapsulated within the polymer. The composite can then be added to any standard skin care formulation. Likewise, hydrophilic fluorophores can be co-dissolved in water along with hydrophilic polymers—such as polyvinyl alcohol; and, again, the solvent (water in this case) can be allowed to evaporate leaving the flouorophore encapsulated within the polymer
[0000] Incorporation of the Fluorescent Dyes into Light Filters—Possible Configurations:
1) UV and HEV-absorbing Fluorophores—Placed in front of the light filter or within the light filter 2) UV and HEV-absorbing Phosphores—Placed in front of the light filter or within the light filter
[0056] The invention introduced here could also serve to underscore the need to make the distinction between damage and repair and to offer more repair options to people.
EXAMPLE 1
[0057] A coating comprising a fluorescent dye with near IR emission over a transparent substrate was made as follows: 0.074 g of polymethylmethacrylate was co-dissolved with a solution of N-(3-triethylammoniumpropyl)-4-(6-(4-(diethylamino)phenyl) hexatrienyl)pyridiniumdibromide, obtained from Life Technologies as the fluorescent dye. (1 mg of dye dispersed in 1.3 mL of toluene) to yield a solution of PMMA (0.065%) and dye (77%). 0.25 microliters of this solution was deposited onto a clear acrylic sheet 2 mm thickness. The toluene was allowed to evaporate at room temperature (about 22 degrees C.) to form a solid, thin film approximately 20 mm in diameter. The excitation/emission spectrum of the fluorescent dye is shown in FIG. 5 .
EXAMPLE 2
[0058] A coating similar to Example 1 was prepared using Quantum Dots (1 mg of non-polar non-functionalized, dodecanethiol coated, heavy metal free CuInS2/ZnS fluorescent nanocrystals, Catalog No. CIS-690-P-1 purchased from AC Diagnostics, and dispersed in 1.3 mL of toluene) to yield a solution as the fluorescent dye. The emission spectrum of this fluorescent dye has a maximum at 690 nm and an excitation band throughout the visible spectrum. | Ophthalmic lenses and light filters containing special additives that have fluorescence emission in the near infrared region of wavelengths—in order to enhance phototherapy for the human eye when it is exposed to sunlight and artificial lighting. | 6 |
TECHNICAL FIELD
[0001] The technical field relates to a motor vehicle having a plurality of doors secured by locks, and a centralized locking system capable of switching the locks between locked and unlocked states.
BACKGROUND
[0002] A motor vehicle is known e.g. from DE 10 2009 010 509 A1. The centralized locking system of such a conventional motor vehicle comprises a central control unit that is adapted to receive a remote control signal and to address, in reaction to the remote control signal, peripheral control units of the doors which, in turn, switch the locks of the doors between locked and unlocked states. In the locked state, the door locks do not react upon operation of external handling means installed at an outer side of the doors; from the unlocked state, a door lock can be brought into a released state by operation of its associated external handling means. In the released state the door is freely displaceable between closed and open positions.
[0003] In each door of this conventional vehicle, the external handling means and an internal handling means are mechanically connected to the lock. Elements required for transmitting an operating force between one of the handling means and its associated lock must be adapted to the shape of the door and to the placement of the handling means and the lock within the door. Therefore, they must be developed and manufactured specifically for each vehicle model, and, in comparison to parts that can be used for a plurality of vehicle models, they are rather expensive.
[0004] The diversity of parts required for different vehicle models makes the logistics of the manufacturing process complicated and laborious. Therefore, it is desirable to use, in the locking system of a motor vehicle, as few model-specific parts as possible. One way to reach this goal is to use an electrically operated locking system. From the technical point of view, it is easy to connect external and internal handling means of a door to an electric switch, the position of which is detected by a central control unit, and to have the central control unit send command signals corresponding to the detected switch position to the door locks. However, there is the problem that if in case of an accident the central control unit, its energy supply or a signal path between the central control unit and a door lock is damaged and one or more locks may operate in less than an optimal manner.
[0005] In view of the foregoing, at least one object is therefore to provide a motor vehicle which ensures sufficient operativeness of the doors without requiring a mechanical coupling between handling means and locks of the doors. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
[0006] A motor vehicle is provided with a plurality of doors secured by locks, peripheral control units, each of which is connected to one of said locks for sending a command signal to an actuator of said lock, and a central control unit for sending command signals to the actuators of said locks, the vehicle further comprising at least one accident detector, wherein, if the accident detector has detected an accident, at least one of the actuators is adapted to be switched from a central operating mode in which it executes commands signals of the central control unit and of the peripheral control unit associated to it, into a peripheral operational mode in which it executes only command signals of its associated peripheral control unit. Preferably all actuators are thus adapted to be switched between central and peripheral operation modes.
[0007] If the actuator has two inputs for receiving command signals from the central control unit and from its associated peripheral control unit, respectively, the switching of the operating mode must occur at the actuator itself, so that it will ignore signals which arrive at the input connected to the central control unit while accepting those from the peripheral control unit. It is simpler if the peripheral control unit is located on a signal path between the central control unit and the actuator and is adapted not to transmit a command signal received from the central control unit while in the peripheral operating mode.
[0008] To this effect, the peripheral control unit may comprise a switch controlled by an output signal of the accident detector for interrupting the signal path. A voltaic interruption of the signal path specifically enables to protect the section of the signal path which extends between the peripheral control unit and the lock controlled by it from the effects of a short circuit which may occur due to the accident on a section of the signal path which extends between the central control unit and the peripheral control unit, and thus to maintain operativeness of the signal path between the peripheral control unit and the lock. The peripheral control unit should be connected to an accumulator which is adapted to provide power to the peripheral control unit and/or to its associated actuator if a central power supply of the vehicle, specifically a vehicle battery, should fail due to the accident.
[0009] In case of a slight accident in which the locking system of the vehicle is not damaged, it is desirable to be able to maintain complete operativeness of the central control unit. Therefore, the peripheral control unit is preferably adapted, in case of detection of an accident by the accident detector, to verify operativeness of the central control unit and to switch into peripheral operating mode only if a failure of the central control unit is detected.
[0010] There a several possibilities to carry out such a verification. One of these is that in case of detection of an accident the peripheral control unit sends a request to the central control unit and verifies whether a reply to this request provided by the central control unit is correct. If the peripheral control unit receives no response or a wrong one, it regards the central control unit as defective and passes into peripheral operating mode.
[0011] Alternatively, the central control unit may be adapted, in case of detection of an accident, to output a signal to the peripheral control units of its own motion, and the peripheral control unit passes into to peripheral operating mode if this expected signal is not received within a predetermined time interval after detection of the accident. This predetermined signal may specifically be an unlocking command signal by which the door locks are switched into an unlocked state in which they can be opened from outside.
[0012] Since each peripheral control unit decides for itself whether the signal received from the central control unit is correct and/or timely, the result of the decision can vary for different peripheral control units. In particular, if the signal path is damaged only between one of the peripheral control units and the central control unit, only this peripheral control unit will switch into peripheral operating mode, whereas the other peripheral control units continue in central operating mode.
[0013] In order to minimize the risk of the signal path between a peripheral control unit and its associated lock being damaged in an accident, preferably each peripheral control unit is located within the door, the lock of which it is connected to. If under these circumstances the peripheral control unit or the signal path between it and the door lock is damaged by the accident, the probability is high that the door will not be free to be opened anyway, because it is deformed by the accident or because it is blocked by an object with which the vehicle has collided.
[0014] An external handling device at an outer side of one of the doors and/or an internal handling device at an inner side of the door can be mechanically coupled to a switch belonging to the peripheral control unit of said door. Since there are no serious constraints on the placement of the switch at the door, parts which couple the handling device and the switch do not have to be specific for a vehicle model and can therefore be manufactured in high numbers at low costs.
[0015] In order to ensure that the doors of the vehicle can still be opened even if, e.g., after a long period of non-use, all electric power storage of the vehicle are empty, an auxiliary handling device at the inner side of the door should be mechanically coupled to the lock. Such an auxiliary handling device does not have to be exposed at the inner side of the door. In order to prevent it from being operated by an intruder, e.g. after smashing a window pane, it should rather be hidden, preferably at a location which is made accessible by means of specific tools only.
[0016] The accident detector used within the context of this invention may be an accident detector which is conventionally used for triggering a personal security system such as an air bag or an active hood, e.g. an acceleration sensor. It is also conceivable to associate to each peripheral control unit an accident detector of its own, which is independent from an accident detector controlling the personal security system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
[0018] FIG. 1 is a schematic top view of a vehicle according to an embodiment;
[0019] FIG. 2 is a block diagram of a locking system according to a first embodiment; and
[0020] FIG. 3 is a block diagram of a locking system according to a second embodiment.
DETAILED DESCRIPTION
[0021] The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description.
[0022] A motor vehicle shown in FIG. 1 has a passenger compartment which is accessible by front and rear doors 1 to 4 , and a luggage bay which is accessible by a luggage bay lid which, in the context of the present invention, is regarded as another door 5 . Locking systems 6 of doors 5 are schematically represented in the Fig. as rectangles, the inner structure of which will be explained later referring to FIG. 2 and FIG. 3 . Locking systems 6 are connected by signal lines, not shown in FIG. 1 , to a central control unit 7 which can be located within the vehicle wherever convenient. The central control unit 7 comprises a conventional radio interface for receiving radio signals from a transponder key operated by a user and is adapted to switch the locking systems 6 between locked and unlocked states upon receipt of a corresponding radio signal. Further, the central control unit 7 may be connected to a locking cylinder which may specifically be part of the locking system 6 of driver door 1 , so as to detect the operation of the locking cylinder by a mechanical key inserted in it and to switch the locking systems 6 of the doors jointly between locked and unlocked states according to this operation.
[0023] Further, at each door 1 to 5 or at least one of them, a switch may be provided which is operated by hand from outside and the operation of which causes the central control unit 7 to verify, using the radio interface, whether a fitting transponder key is in the vicinity of the operated switch, and, if yes, to switch the locking systems 6 between the locked and unlocked states. If the vehicle is involved in an accident, communication between the central control unit 7 and the locking systems 6 may be disturbed, be it because, due to an impact from the direction of arrow 8 , the control unit 7 is damaged or because a signal line between the central control unit 7 and the locking systems 6 is intercepted, short-circuited or otherwise damaged. Such damage can occur in particular if the vehicle is hit from the direction of arrow 9 in the vicinity of the hinge of one of doors 1 to 4 , since the signal line will generally penetrate into the door, in case of FIG. 1 into driver door 1 , in the vicinity of its hinge.
[0024] For an understanding of the operation of the locking systems 6 in case of such an incident, it is appropriate first to study their internal structure. FIG. 2 shows in detail the components of the locking system 6 of door 1 ; locking systems of the other doors 2 , 3 , 4 , 5 have the same structure. A lock 10 comprises two members which are displaceable with respect to each other by means of an electric actuator 11 , referred to here as a door member 12 and a body member 13 , which are capable of lockingly engaging in order to fix the door 1 in closed position and which can be disengaged from each other in order to enable opening of the door 1 . The actuator 11 is connected to the central control unit 7 by a signal line which is divided into a central section 15 and a door section 16 by a switch 14 . The door section 16 of the signal line has two switches 17 , 18 connected to it, which, in turn, are coupled to an external handling device 19 such as a door handle, and to an internal handling device 20 , respectively. An operation of the internal handling device 20 by a vehicle occupant causes an unlocking signal to be output to door section 16 by switch 18 . The unlocking signal causes lock 10 , if in its locked state, to switch into the unlocked state. The lock members 12 , 13 are in locking engagement both in the locked and unlocked states, the difference between the two states being that only in the unlocked state a lock 10 will react to a release signal by the actuator 11 disengaging lock members 12 , 13 and thus placing the door 1 in a released state in which it is free to pivot between an open position and a closed position. The release signal can be generated by switch 18 if the internal handling device 20 is displaced beyond the position in which it generates the unlocking signal, or it can be generated by switch 17 if the external handling device 19 is operated.
[0025] The unlocking signal is not generated by switch 17 , so that the door cannot be opened illicitly from outside when in the locked state. It can be provided, however, that switch 17 generates an activation signal instead, which is received by central control unit 7 and causes the latter to verify whether a transponder key fitting the vehicle is in the vicinity and, if yes, to transmit the unlocking signal.
[0026] The switches 17 , 18 receive the electric power needed for generating the various signals from an accumulator 21 , specifically a super capacitor, which is mounted in the door, forming part of its locking system 6 , and is connected to a vehicle battery, located outside the door and not shown in FIG. 2 , by an electric valve 22 . The electric valve 22 ensures that the accumulator 21 is always charged while the vehicle battery is operating, and it prevents the accumulator 21 from discharging via a short-circuit that may be caused on an outside of the door by an accident. For transmitting the various signals mentioned above, the signal line may comprise various conductors associated to the signals. Alternatively, it may be structured as a bus where the various signals circulate in the form of digital information packets.
[0027] The switch 14 is coupled to an acceleration sensor 23 which responds to a sudden deceleration of the vehicle in case of an accident by triggering, in a known manner, a personal protection system not shown here, such as an airbag, an active hood or the like. The same signal which causes the personal protection system to trigger is received by switch 14 and causes it to open. When switch 14 is open, a short-circuit which may be caused by the accident in the central section 15 can no longer prevent signal communication between the switches 17 , 18 and the actuator 11 , so that even in case of a failure of the central control unit 7 or of central line section 15 , opening the door remains possible.
[0028] As indicated by a dash-dot line 24 , the acceleration sensor 23 may be coupled directly to the door section 16 of the signal line, in particular with a conductor thereof that carries the unlocking signal, so that the signal from acceleration sensor 23 which causes switch 14 to open can at the same time have the effect of an unlocking signal on actuator 11 . If the signal line is organized as a bus, line 24 can be replaced by a digital signal source which is controlled by acceleration sensor 23 to output the digital unlocking signal to line section 16 in case of an accident.
[0029] A Bowden cable connected to the door member 12 of lock 10 has the reference numeral 25 assigned to it. A handle of Bowden cable 25 is hidden within the door and can be made accessible by removing a liner at the inner side of the door. By pulling the Bowden cable 25 lock 10 can be brought into released state even if, e.g. due to a long rest period both the battery of the vehicle and the accumulator 21 are discharged.
[0030] FIG. 3 illustrates a second embodiment of the locking system 6 . While in the embodiment of FIG. 2 a peripheral control unit that controls actuator 11 in case of a failure of central control unit 7 is substantially made up of switches 14 , 17 , 18 , in the embodiment of FIG. 3 such a peripheral control unit 26 is formed by a digital circuit. In normal operation this peripheral control unit 26 forwards locking and unlocking signals received from the central control unit 7 to the actuator 11 without modifying them, monitors the position of switches 17 , 18 and, if necessary, generates locking, unlocking or releases signals of its own if the switches 17 , 18 are in a position corresponding thereto.
[0031] The peripheral control units 26 of doors 1 to 5 can be connected to the same acceleration sensor 23 as shown in FIG. 2 , which in case of an accident triggers the personal security systems. Alternatively, and as shown in FIG. 3 , each door 1 to 5 may have an acceleration or shock sensor 27 of its own which responds to the collision or to the shock caused by the blast of an airbag triggered by sensor 23 . The risk of an interruption of the signal path between sensor 27 and peripheral control unit 26 is minimized by the sensor 27 being installed in the same door as the peripheral control unit 26 to which it is connected.
[0032] If the acceleration sensor 23 detects an accident and the central control unit 7 is still operative, it reacts by transmitting an unlocking signal. If the central line section 15 is also undamaged the signal is received by the peripheral control units 26 of all doors 1 to 5 . All peripheral control units 26 that receive the unlocking signal thus recognize that the central control unit 7 is still operational after the accident, and they continue to forward signals from the central control unit 7 to the actuators 11 controlled by them. However, if one of the peripheral control units 26 , e.g. in door 1 , receives no unlocking signal from central control unit 7 while at the same time sensor 27 indicates an accident, peripheral control unit 26 detects a failure. By having this peripheral control unit 26 ignore signals that subsequently arrive from central line section 15 , operability of the peripheral control unit 26 is ensured in spite of the accident. Control unit 26 then autonomously and automatically transmits the unlocking signal to the actuator 11 of door 1 , so that door 1 can be opened from inside and outside.
[0033] While at least one exemplary embodiment has been presented in the foregoing summary and detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. | A motor vehicle has a plurality of doors, each secured by a lock, peripheral control units, each connected to one of said locks, for sending a command signal to an actuator of the lock, a central control unit for sending command signals to the actuators of the locks, and an accident detector. If the accident detector has detected an accident, at least one of the actuators is switchable from a central operating mode in which it executes command signals of the central control unit and its associated peripheral control unit into a peripheral operating mode in which it executes only command signals from its peripheral control unit. | 8 |
This application is a divisional of application Ser. No. 08/730,935 filed Oct. 16, 1996, which is a continuation of Ser. No. 08/391,461 filed Feb. 21, 1995, now U.S. Pat. No. 5,633,856 which is a continuation of Ser. No. 08/005,159 filed Jan. 15, 1993, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a disc table employed in a disc recording/reproducing apparatus for a recording disc, such as an optical disc or a magneto-optical disc, on which information signals are to be recorded or pre-recorded. More particularly, the present invention relates to such disc table having a centering member enabling the recording medium to be loaded and centered with respect to the disc table. The present invention also relates to a method for producing the disc table.
2. Description of the Related Art
Recently, recording discs such as optical discs or magneto-optical discs, and a recording/reproducing apparatus employing such recording discs as a recording medium, have been proposed.
In the above-described recording/reproducing apparatus, when recording information signals on the recording disc or reproducing information signals recorded on the recording disc, the disc is rotated with a pickup unit which acts as a recording and/or reproducing means for the information signals facing a signal recording surface of the disc. To this end, there is provided in the disc recording/reproducing apparatus a disc rotating and driving mechanism having a disc table on which the recording disc is loaded and which is adapted to be rotated in unison with the disc. As such disc table employed in the disc rotating and driving mechanism, there is known a disc table disclosed in, for example, U.S. Pat. No. 4,068,851 to Yamamura and U.S. Pat. No. 4,340,955 to Elliott et al.
The disc table constituting the above-described disc rotating and driving mechanism comprises a table section integrated with a driving shaft of a rotating driving motor which function as a rotating and driving means, and a fitting member mounted at the middle of the table section which engages a center aperture of the recording disc set on the table section.
The disc table includes a thrusting and supporting mechanism for thrusting and supporting the recording disc set on the table section and insert in a predetermined position. The thrusting and supporting mechanism comprises a chucking plate mounted facing the table section and adapted to clamp the rim of the center aperture of the recording disc set on the table section in position on the table section.
The fitting member is substantially frusto-conical, with tapered towards its upper or distal end.
The fitting member is supported for movement along the axis of the driving shaft, while being resiliently biased by a biasing member, such as a spring, towards its upper end.
With the above-described disc table, in which the outer periphery of the fitting member is tapered and upwardly biased, when the recording disc is set on the table section, with the rim of the center aperture thereof in sliding contact with the outer periphery of the fitting member, the rim of the center aperture is thrust by the outer periphery of the fitting member to effect centering of the recording disc with respect to the driving shaft.
When the driving motor is driven for rotating the driving shaft, the recording disc is rotated in unison with the disc table.
Meanwhile, the above-described disc table in which the fitting member for centering the recording disc with respect to the disc table is supported for movement relative to the table section is complex in construction and difficult to assemble and manufacture. Besides, with this disc table, since it is necessary to provide the spring between the fitting member and the table section, it is difficult to achieve reduction in height of the table section.
To overcome this drawback, a disc table has been proposed in which the fitting member is fixedly provided with respect to the table section to achieve a simplified construction and a reduction in the height of the apparatus. However, it is necessary with this disc table design that the fitting member be smaller in size with respect to the center aperture in order to allow for the dimensional error of the outer diameter of the fitting member and the dimensional error of the inside diameter of the center aperture. Consequently, with such disc table, a very small clearance tends to be occur between the outer periphery of the fitting member and annual inner rim of the center aperture when the recording disc is set on the table section.
If such clearance is produced between the fitting member and the center aperture, not only can the centering of the recording disc with respect to the driving shaft not be achieved, but also the recording disc tends to shift relative to the table section in response to external vibrations or shock.
Further, with the above-described recording/reproducing apparatus, if the offset of the recording disc with respect to the driving shaft of the disc rotating and driving mechanism is sufficiently large, the light beam from the pickup unit for writing and/or reading information signals on or from the recording disc cannot follow the recording track of the recording disc and renders it impossible to record and/or reproduce the information signals. Additionally, with such disc recording/reproducing apparatus, if the recording disc shifts with respect to the table section in the course of recording and/or reproduction of the information signals, the light beam undergoes track jump to interrupt recording/reproduction process.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a disc table whereby a recording disc may be loaded on the disc table with a high centering accuracy with respect to the center of rotation of a disc rotating and driving mechanism.
It is another object of the present invention to provide a disc table whereby the effects of extraneous vibrations or shock on the loaded recording disc may be inhibited and thus ensure stable rotation of the recording disc.
It is a further object of the present invention to provide a disc table which is simplified in construction and reduced in height and which contributes to reduction in the thickness of the recording/reproducing apparatus.
It is yet another object of the present invention is to provide a method for producing a disc table whereby a disc table capable of achieving the above objects may be produced easily.
The present invention provides a disc table for a disc recording/reproducing apparatus employing a recording disc, such as an optical disc or a magneto-optical disc, on which information signals are pre-recorded or are to be recorded, as a recording medium. The disc table includes a fitting member fitted from its distal end into a circular center aperture of the recording disc, a table section which is integrated to the fitting member at a proximal side of the fitting member and on which a rim around the center aperture of the disc is set, a thrusting supporting unit for thrusting and supporting the recording disc with respect to the table section, and a centering unit provided at a proximal side of the fitting member and adapted for thrusting the rim around the center aperture of the recording disc for coinciding the center of rotation of the recording disc with the center of rotation of the fitting member. The fitting member is gradually tapered towards its distal end where the fitting member is provided with a guide slidingly contacted with the inner rim of the center aperture of the recording disc for guiding the recording disc towards the center of rotation of the fitting member. The recording disc may be positively centered to enable stable rotation of the recording disc while realizing a simplified thin type construction.
As means for thrusting and supporting the recording disc placed on the table section with respect to the table section, a magnet for attracting a magnetic metal plate mounted at the center of the recording disc is employed.
The proximal side of the fitting member fitted in the center aperture of the recording disc is formed as a columnar section having an outside diameter corresponding to the diameter of the center aperture of the recording disc.
The centering members are formed as plural spring plates mounted on the fitting member for being projected out of or receded inwardly of the outer peripheral surface of the proximal end of the fitting member.
The plural spring plates of the centering members are arranged on the fitting member in a state in which the spring plates are resiliently biased towards the center of the fitting member and which is controlled by resetting controlling means provided at the mid part of the table section.
The centering members are constituted by spring plates formed of a metallic material.
When the centering members are formed as spring plates of metallic material, both lateral sides of the portions of the centering members abutted against the inner rim of the center inn of the recording disc are bent substantially arcuately towards the center of the fitting member.
The present invention also provides a method for producing a disc table comprising positioning a fitting member by fitting a reference shaft of a positioning jig in a center aperture of said fitting member, placing centering means having plural centering members in the form of spring plates thrusting the inner rim of the center inn of the recording disc so that the centering members are positioned at the peripheral side of the fitting member, abutting each of the centering members with a substantially equal thrusting force on an abutment inner wall section of a positioning hole formed in a positioning jig with said reference shaft as a center for positioning said centering means with respect to said fitting member, and immobilizing and attaching said centering means in position with respect to said fitting member.
With the above-described disc table, the fitting member having a gradually tapered distal end and provided with a disc-capturing guide section at the distal end is intruded from the tapered distal end first into the circular center aperture of the recording disc and moved towards the proximal end of the fitting member so as to be guided towards the center region by the disc-capturing guide section. The disc is thrust and supported by thrusting supporting means with respect to the table section provided at the proximal end of the fitting member and has the inner rim of the center aperture thereof thrust by the centering means provided at the proximal end of the fitting member for effecting centering with respect to the disc table.
When a magnet attracting a metallic plate fitted at the center of the recording disc is employed as the thrusting supporting means for the recording disc, the recording disc is held only at one of its sides.
When the proximal side of the fitting member is designed as a columnar section, the recording disc when placed on the table section has its center aperture in intimate abutment contact with the proximal side of the fitting member to inhibit movement of the recording disc with respect to the table section.
When the centering means is constituted by centering members in the form of plural spring plates, arranged for being protruded from or receded inwardly of the outer periphery of the fitting member, the centering members may be integrated with the fitting member to simplify the construction of the disc table.
When the centering members in the form of spring plates are provided in the fitting member in a state in which they are resiliently biased towards the center of the fitting member and which is controlled by a controlling section provided at the center of the table section a sufficient thrusting force is applied to the recording disc by the centering members even although the centering members are of a lower spring constant. Besides, the fluctuations in the thrusting force applied to the recording disc as a result of errors in the spring constant may also be diminished.
When the centering members of the disc table are formed as spring plates of a metallic material, the centering members exhibit superior durability even under hostile environment such as elevated temperatures, while satisfactory characteristics with only small error rate may be achieved even although the spring constant of the centering members is increased.
When both lateral sides of the portions of the centering members formed as spring plates of a metallic material abutted against the inner rim of the center aperture of the recording disc are bent substantially arcuately towards the center of the fitting member, the recording disc is not injured by the centering members during disc loading and unloading and may be smoothly loaded or unloaded on the disc table.
The method for producing the disc table according to the present invention comprises positioning a fitting member to be intruded from its distal end first into the circular center opening of the recording disc by fitting a reference shaft of a positioning jig in a center aperture of the fitting member, placing the centering means so that its centering members in the form of plural spring plates thrusting the inner rim of the center aperture of the recording disc are positioned at the peripheral side of the fitting member, abutting each of the centering members with a substantially equal thrusting force on an abutment inner wall section of a positioning hole formed in the positioning jig coaxially with the reference shaft for positioning the centering means with respect to the fitting member, and immobilizing and attaching the centering means in position with respect to the fitting member, so that the centering means may be mounted at a position such that the inner rim of the center aperture of the recording disc may be uniformly thrust by the respective centering members.
Other objects and advantages of the present invention will become clear from the following description of the preferred embodiments and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing an arrangement of a disc table according to the present invention.
FIG. 2 is a longitudinal sectional view showing the arrangement of the disc table shown in FIG. 1.
FIG. 3 is an exploded perspective view showing the arrangement of the disc table shown in FIG. 1.
FIG. 4 is an enlarged longitudinal cross-sectional view showing essential portions of the disc table shown in FIG. 1.
FIG. 5 is an enlarged longitudinal sectional view showing the state in which the loading of the recording disc on the disc table is started.
FIG. 6 is an enlarged longitudinal sectional view showing the state in which the recording disc is being loaded on the disc table.
FIG. 7 is an enlarged longitudinal sectional view showing the state in which the loading of the recording disc on the disc table is completed.
FIG. 8 is a plan view showing an embodiment of the dias table of the present invention in which the fitting member is integrated to the centering member.
FIG. 9 is a longitudinal cross-sectional view showing the arrangement of the disc table shown in FIG. 8.
FIG. 10 is an exploded perspective view showing an embodiment of the disc table according to the present invention in which plural clamping members make up thrusting supporting means.
FIG. 11 is a longitudinal cross-sectional view showing arrangements of the disc table shown in FIG. 10 and the disc table loaded thereon.
FIG. 12 is a longitudinal cross-sectional view showing the state in which the loading of a disc cartridge on the disc table shown in FIG. 10 is started.
FIG. 13 is a longitudinal cross-sectional view showing the state in which the disc cartridge is being loaded on the disc table shown in FIG. 10, with the clamping members being in a neutral position.
FIG. 14 is a longitudinal cross-sectional view showing the state in which the disc cartridge is being loaded on the disc table shown in FIG. 10, with the clamping members being biased downwards.
FIG. 15 is a longitudinal cross-sectional view showing the state in which the loading of a disc cartridge on the disc table shown in FIG. 10 is completed.
FIG. 16 is a longitudinal cross-sectional view of a modification of the essential parts of the disc table showing the state in which the loading of a disc cartridge on the disc table is started.
FIG. 17 is a longitudinal cross-sectional view showing the state in which the loading of a disc cartridge on the disc table shown in FIG. 16, is completed.
FIG. 18 is a longitudinal cross-sectional view of another modification of the essential parts of the disc table showing the state in which the loading of the disc cartridge on the disc table is started.
FIG. 19 is a longitudinal cross-sectional view showing the state in which the loading of the disc cartridge on the disc table shown in FIG. 18 is completed.
FIG. 20 is a plan view showing an embodiment in which a disc table according to the present invention is constituted using a centering member consisting in a spring plate formed of a metallic material.
FIG. 21 is a longitudinal cross-sectional view showing a construction of the disc table shown in FIG. 20.
FIG. 22 is an exploded perspective view showing the construction of the disc table shown in FIG. 20.
FIG. 23 is a perspective view illustrating the method for producing the disc table according to the present invention showing the process for producing the disc table shown in FIG. 20.
FIG. 24 is an enlarged longitudinal sectional view showing the recording disc being loaded on the disc table shown in FIG. 20.
FIG. 25 is an enlarged longitudinal sectional view showing the state in which the loading of the recording disc on the disc table shown in FIG. 20 is completed.
FIG. 26 is an enlarged longitudinal sectional view showing another modification of a disc table according to the present invention in which the disc member is constituted using a centering member of a spring plate formed of a metallic material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, illustrative embodiments of the present invention will be explained in detail.
Referring to FIGS. 1 to 3, showing a first embodiment of the disc table of the present invention, the disc table has a table section 2 fitted on a driving shaft 1 of a spindle motor 5 of a disc recording/reproducing apparatus in which the disc table is fitted. The table section 2 is formed substantially as a disc from synthetic resin or the like material and has an engaging aperture which is a center aperture engaged by the driving shaft 1. An outer peripheral region of an upper surface of the table section 2 is a disc setting surface 3 on which the recording disc 101 as a recording medium is set.
On the lower surface of the table section 2, there is formed a cylindrical supporting section 7, centered about the engaging aperture 8. The function of the supporting section 7 is to increase the length of the engaging aperture 8 so as to be larger than the thickness of the table section 2 for assuring more positive support of the table section 2 by the driving shaft 1.
The recording disc 101 loaded on the disc table comprises a disc-shaped disc substrate 101a formed of a light-transmitting transparent synthetic resin and a signal recording layer formed on one of the major surfaces of the disc substrate 101a, as shown in FIGS. 3 and 4. The disc substrate 101a has a circular center aperture 102. This circular aperture serves as a reference for the loading position of the disc on the disc table provided within the disc recording/reproducing apparatus.
On the opposite major surface of the disc substrate 101a is formed an annular rib surrounding the center aperture 102. On the major surface of the disc substrate carrying the signal recording surface is formed an annular recess 103 surrounding the center aperture 102 in register with the annular rib, as shown in FIG. 3. A substantially disc-shaped magnetic plate 104, formed of a magnetic material, such as metal, is set within the recess 103. The magnetic plate 104 is retained by the disc substrate 101a by means of an adhesive or supporting lugs formed by thermally deforming part of the disc substrate 101a formed e.g. of synthetic resin.
The signal recording layer, deposited on the firstly-mentioned major surface of the disc substrate 101a, is formed of a metallic material for providing a perpendicular recording magnetic film and a reflective layer for reflecting the light beam, and is used for recording desired information signals.
The spindle motor 5 is mounted on the lower surface of a chassis 6 of the disc recording/reproducing apparatus, and has its driving shaft 1 extended above the chassis 6 via a through-hole in the chassis 6, as shown in FIG. 2. Above the chassis 6, an optical pickup device and a magnetic head device, not shown, for recording and/or reproducing information signals with respect to the signal recording layer of the magneto-optical disc 101 placed on the disc setting surface 3, are provided for movement towards and away from the spindle motor 5, that is in a direction spanning the inner and outer peripheries of the recording disc 101.
A fitting member 4 is provided at the center of the upper surface of the table section 2. The fitting member 4 is substantially conically-shaped and integrated to the table section 2. The fitting member 4 is of an outside diameter large enough to be fitted in the center aperture 102 of the recording disc 101. The fitting member 4 has its upper end, that is the distal end, as a disc-capturing tapered guide section 4a which is tapered towards its end surface, as shown in FIG. 4. The outer peripheral surface of the disc-capturing guide section 4a is curved smoothly so as to be merged with the end face of the fitting member 4. The fitting member 4 also has its distal side, that is its side proximate to the disc setting surface 3, as a columnar section 4b which is of an outside diameter substantially equal to the inside diameter of the center aperture 102 of the recording disc 102.
The outer periphery of the fitting member 4 is formed with a groove 25 engaged by a centering ring 11 constituting centering means, as shown in FIG. 3. The groove 25 has a depth extended from the distal end to a mid part of the fitting member 4 and is in the form of a annulus or toroid coaxial with the fitting member 4. The fitting member 4 has an outer peripheral upright wall delimiting the groove 25. The peripheral wall has plural cut-outs 10 in communication with the groove 25. These cut-outs 10 are extended radially from the groove 25 towards the outer surface of the fitting member 4. These cut-outs 10 are provided at equiangular intervals about an axis of the fitting member 4 as a center.
The centering ring 11, fitted into the groove 25 of the fitting member 4, is also formed as a toroid or annulus from metal or synthetic resin exhibiting flexibility and elasticity. The centering ring 11 is formed integrally with plural outwardly directed centering segments 12 for centering the recording disc loaded on the disc table. These centering segments 12 are tongue-shaped concentric radially extending lugs at equiangular intervals so as to be in register with the cut-outs 10. These centering segments 12 are in the form of spring plates so as to be deformed resiliently.
When the centering ring 11 is fitted in the groove 25, the centering segments 12 are positioned in such a manner that the proximal ends thereof are in proximity to the end face of the fitting member 4 and the distal ends thereof are directed at an angle with respect to the disc setting surface 3 and partially projected outwardly of the cut-outs 10, that is towards the outer periphery of the fitting member 4. The distal end parts of the centering segments 12 are extended on the periphery of the columnar section 4b in the direction of the disc setting surface 3. That is, the centering segments 12 are extended outwardly of the fitting member 4 at the proximal side of the fitting member 4. The distal end parts of these centering segments 12 may be intruded into and protruded out of the cut-outs 10 by the elastic deformation of the proximal pars of the centering segments 12.
Meanwhile, a toroidal-shaped groove 14 enveloping the end parts of the centering segments 12 is formed on the upper surface of the table section 2 in order to allow for elastic deformation of the centering segments 12.
The end face of the fitting member 4 is formed with a magnet mounting recess 13 which is a circular recess concentric with the fitting member 4. A magnet 9 for thrusting and supporting the recording disc 101 with respect to the table section 2 is fitted in the mounting recess 13. The magnet 9, in the form of a circular button, is adapted for magnetically attracting a magnetic plate 104 which is mounted at a mid-part of the recording disc 101 for closing the center aperture 102.
For loading the recording disc 101 on the above-described disc table according to the present invention, the recording disc 101 is fitted by its center aperture 102 over the fitting member 4, as shown in FIG. 4. Since the end face section of the fitting member 4 is smoothly merged with its disc capturing taper section 4a, the recording disc 101 is guided towards the mid-part of the fitting member 4 so as to be moved towards the distal end of the fitting member 4, with the inner rim of the center aperture 102 being in sliding contact with the outer surface of the disc capturing taper section 4a, under magnetic attraction exerted by the magnet 9 on the magnetic plate 104, even although the disc 101 is offset with respect to the fitting member 4.
When the recording disc 101 is moved towards the proximal side of the fitting member 4, the inner rim of the center aperture 102 is caused to bear on the centering segments 12, as shown in FIGS. 5 and 6. The disc 101 is moved towards the proximal side of the fitting member 4, with its inner rim abutting on and elastically deforming the centering segments 12 for intruding the segments 12 into the cut-outs 10. The centering segments 12 thrust the inner rim of the center aperture 102 outwards under their elasticity.
When the recording disc 101 is fitted on the columnar section 4b of the fitting member 4 by its center aperture 102 and the neighboring portion to the aperture 102 of the disc is set on the disc setting surface 3, the disc 101 is centered by the inner rim of its center aperture 102 thrust by the centering segments 12, with the center of the center aperture 102 being then in register with the axis of the fitting member 4, as shown in FIG. 7.
The magnet 9 then attracts the magnetic plate 104 mounted on the recording disc 101 for pressing the disc 101 against the disc setting surface 3.
When the recording disc 101 is loaded in this manner in position on the table section 2, and the driving shaft 1 is run in rotation by spindle motor 5, the recording disc 101 is rotated in unison with the table section 5. The information signals may then be recorded and/or reproduced on or from the signal recording layer of the recording disc 101 by the optical head device or the magnetic head device.
Meanwhile, for satisfactory centering, it is necessary for the centering segments 12 to thrust the inner rim of the center aperture 102 towards the table section 2 with a sufficient pressure before the recording disc 101 is caused to bear against the disc setting surface 3. When the inner rim of the center aperture 102 of the recording disc 101 abuts on the centering sections 12, a disc attracting force F by which the magnet 9 attracts the magnetic plate 104 as indicated by arrow F in FIG. 5, a reactive force N exerted by the centering segment 12 in a normal direction shown by arrow N in FIG. 5 on the inner rim of the center aperture 102, and a thrusting force f by which the inner rim of the center aperture 102 thrusts the centering segment 12, as indicated by arrow f in FIG. 5, are generated for each of the centering segments 12. Assuming that the centering ring 11 is provided with six centering segments 12, it is necessary that the formula
f=N sin θ=(F/6)×(sin θ/cos θ) (1)
be satisfied. In the above formula, θ is an angle by which the outer lateral surface of the centering segment 12 is inclined relative to the major surface of the recording disc 101. If the disc attracting force F is 350 gf and the angle θis 70°, the thrusting force f is given by
f=(350/6)×tan 70°=160 gf (2)
and hence is 160 gf. That is, it suffices to set the elasticity of the centering segments so that, when the centering segment 12 is thrust by the thrusting force exceeding 160 gf, the centering segment 12 is resiliently biased by an amount α by which the centering segment 12 is protruded beyond the fitting member 4 on a horizontal plane including the disc setting surface 3. It is because the centering segments 12 are resiliently deflected by an amount equal to the amount the segments 12 are protruded from the fitting member 4 on the horizontal plane inclusive of the disc setting surface 3 when the recording disc 101 is set on the disc setting surface 3.
Meanwhile, the centering segments 12, exhibiting the resiliency such that the segments 12 are resiliently protruded by an amount of protrusion from the fitting member 4 on the horizontal plane inclusive of the disc setting surface 3 when the segments are thrust by the thrusting force f equal to about 160 gf, may be formed of a synthetic resin material.
A disc table according to a second embodiment of the present invention is hereinafter explained.
In the second embodiment of the disc table, the centering segments 12 may be integrated with the fitting member 4, as shown in FIGS. 8 and 9. That is, the fitting member 4 of the present second embodiment is made up of the fitting member 4 integrated to the centering ring 11 of the preceding embodiment.
A disc table according to a third embodiment of the present invention is hereinafter explained.
In the present third embodiment of the disc table, a plurality of clamping members 19 are provided as thrusting and supporting means, as shown in FIGS. 10 to 15. The disc table of the present embodiment is designed to hold the recording disc 101 housed for rotation in a cartridge main body to constitute a disc cartridge. In distinction from the recording disc 101 of the preceding embodiments, the recording disc 101 of the present embodiment is not fitted with the magnetic plate 104.
The disc cartridge is made up of the recording disc 101 and a cartridge main body 104 housing the recording disc 101 therein, as shown in FIG. 11. The cartridge main body 104 is formed as a substantially rectangular casing for accommodating the recording disc 101 therein. That is, the cartridge main body 104 has a substantially square shape having a side of each of the upper and lower major surfaces extending along the major surfaces of the recording disc 101 slightly longer than the diameter of the recording disc 101. The recording disc 101 is accommodated for rotation within the cartridge main body 104.
A substantially circular chucking aperture 108 is formed in the lower major surface of the cartridge main body 104. The chucking aperture 108 is a through-hole slightly larger in diameter than the center aperture 102 of the recording disc 101 and functions to expose the center aperture 102 and its rim portion to outside.
A recording/reproducing aperture, not shown, is formed in each of the major surfaces of the cartridge main body 104. Each recording/reproducing aperture is provided for extending from the vicinity of the center of one of the major surfaces of the cartridge main body 104 as far as one of the sides of the major surface, that is the vicinity of one of the lateral sides of the cartridge main body 104. The function of these recording/reproducing apertures is to cause the optical pickup device or the magnetic head of the disc recording and/or reproducing apparatus to face the recording disc 101 when recording and/or reading the information signals on or from the signal recording surface of the recording disc 101.
A pair of annular ribs 106, 107 for controlling the movement along the thickness of the recording disc 101 within the cartridge main body 101 are formed in the vicinity of the rim of the center aperture 102 of the recording disc 101 at opposite positions on the inner wall sections of the cartridge main body 104.
The disc table of the present third embodiment is provided with a table section 2, as is the disc table of each of the first and second embodiments, as shown in FIG. 10. The table section 2 has the outer peripheral region of its upper surface as the above-mentioned disc setting surface 3 and has a fitting member 4 protuberantly mounted at the mod part of its upper surface. The fitting member 4 has plural centering segments 12.
With the present disc table, the fitting member 4 has plural clamping members 19, 19, 19 each having its mid-part supported for rotation. These clamping members 19 are mounted in radially extending clamping member mounting slits 15, 15, 15 provided in the fitting member 4. These clamping members 19 are supported by supporting shafts 17 which are provided in the clamping member mounting slits 15 and which are passed through shaft inserting holes 20 provided at the mid-part of the clamping members 19. The supporting shafts 17 are formed so that the axial directions thereof extend along the tangent of a circle having the center axis of the table section 2 as a center. The clamping member 19 is formed as a substantially T-shaped member having arms extending in two opposite directions form the mid-part provided with the shaft inserting hole 20 and a third arm extending in a direction substantially normal to these two arms. One of the two arms of the clamping member 19 extending in the two opposite directions functions as the clamping section 23, while the third arm extending in the direction substantially normal to the clamping section 23 functions as a thrust section 22.
Each of the clamping sections 19 in its initial state has the thrust section 22 protruded radially out of the fitting member 4 so as to overlie the disc setting surface 3, while having the clamping section 23 housed within the clamping member mounting slit 15, as shown in FIG. 11. Since each of the clamping sections 19 in its initial state is housed within the clamping member mounting slit 15, there is no fear of the clamping member 19 being rotated or damaged by foreign matter or the user's finger being inadvertently introduced at the distal end of the fitting member 4.
Meanwhile, the clamping member mounting slits 15 are each formed for extending as far as a position of the disc setting surface 3 faced by the thrust sections 22.
Between each clamping member 19 and the table section 2, a torsion coil spring 18 for rotationally biasing the clamping member 19 in a direction away from a neutral rotational position of the clamping member 19 is provided in association with each clamping member 19. Each of the torsion coil springs 18 resiliently biases a retention pin 21, provided on the other of the two arm sections extended in the two opposite directions, that is the arm section opposite to the clamping section 23 with the shaft inserting opening in-between, in a direction outwardly of the table section 2. Each of the torsion coil springs 18 has one of its arm sections engaged with an engaging pin 21 of each of the clamping members 19, while having the other arm section retained by a retention section 24 provided in each of the clamping member mounting slits 15. The clamping members 19, 19, 19 are rotationally biased at this time so that the thrust sections 22 thereof are directed to the upper end face of the fitting member 4 in FIG. 10, as indicated by arrows D in FIGS. 11 and 12.
The neutral rotational position of the clamping member 19 is the position at which it has been turned from the above-mentioned initial state in a direction of shifting the thrust section 22 towards the disc setting surface 3, and at which the retention section 24, retention pin 21 and the supporting shaft 17 are on a straight line, as shown in FIG. 13. In this state, each of the torsion coil springs 18 biases the associated clamping member 19 in a direction proceeding from the retention pin 21 towards the supporting shaft 17, as shown by arrow E in FIG. 13. That is, the torsion coil spring 18 rotationally biases the associated clamping member 19 in a direction shown by arrow D in FIGS. 11 and 12 when the clamping member 19 is at a position rotated in one direction from the neutral position, as shown in FIGS. 11 and 12. On the other hand, when the clamping member 19 is at a position rotated in the opposite direction from the neutral position, as shown in FIGS. 14 and 15, the torsion coil spring rotationally biases the clamping member 19 in the opposite direction as indicated by arrow in FIGS. 14 and 15.
With the above-described disc table of the third embodiment according to the present invention, when the operation of setting the recording disc 101 on the table setting surface 3 of the table section 2 is initiated, as shown by arrow C in FIG. 12, the distal end of the fitting member 4 is inserted into the center aperture 102 of the recording disc 101. The recording disc 101 has its set section 105 around its center aperture 102 on its opposite major surface abutted against the thrust section 22.
When the recording disc 101 is moved towards the disc setting surface 3, each clamping member 19 has its thrust section 22 thrust by the set section 105 of the recording disc so that the thrust section 22 is rotated in a direction of approaching the disc setting surface 3 against the bias of the torsion coil sparing 18, as shown in FIG. 13. Each of the clamping members 19 is rotated in this manner to the above-mentioned neutral rotational position.
When the recording disc 101 is moved towards the disc setting surface 3, each clamping member 19 has its thrust section 22 thrust by the set section 105 of the recording disc 101, as shown in FIG. 13, so that the thrust section 22 is rotated against the bias of the torsion coil spring 18 in a direction of approaching the disc setting surface 3. In this manner, the clamping section 19 is rotated to the above-mentioned neutral rotational position.
When the recording disc 101 further approaches the disc setting surface 3, the thrust section 22 of each of the clamping members 19 is thrust by the set section 105 of the recording disc 105, so that the thrust section 22 is rotated beyond the neutral rotational position in a direction of approaching the thrust section 22 to the disc setting surface 3, as shown in FIG. 14. At this time, each clamping section 19 causes the thrust section 22 to be rotated in a direction of further approaching to the disc setting surface 3, under the bias of the torsion coil spring 18 and under the thrusting force exerted by the set section of the disc on the thrust section 22, as indicated by arrow G in FIG. 14. The cartridge main body 104 is loaded in position on a chassis 6 by being caused to bear against he distal ends of positioning pins 202, 203 mounted upright on the chassis 6.
Meanwhile, the table section 2 is intruded into the inside of the cartridge main body 104 via chucking aperture 108 provided in the cartridge main body 104.
Under the thrust exerted by the set section 105 against the thrust section 22 and the bias exerted by the torsion coil spring 18, each clamping member 19 causes the thrust section 22 to be rotated in a direction of approaching to the disc setting surface 3. The clamping members 19 cause the thrust sections 22 to be moved away from the set section 105, while causing the clamp sections 23 to bear against a recess 103 formed in the rim of the center aperture 102 in one of the major surfaces of the recording disc 101. The result is that the recording disc 101 is thrust and supported on the disc setting surface 3 by the clamping member 19, as shown in FIG. 15. At this time, the recording disc 101 has its center of rotation coincided with the axis of the disc table by the centering segments 12 of the fitting member 4 by way of performing a centering operation.
If the spindle motor 5 rotates the driving shaft 1 at this state, the recording disc 101 is rotated in unison with the table section 2. The information signals may be recorded on or reproduced from the signal recording layer by the optical pickup device or the magnetic head device.
For dismounting the recording disc 101 from the table section 2, it suffices to move the recording disc 101, along with the cartridge main body 104, in an upward direction away from the disc setting surface 3. Each of the clamping members 19 has its clamping section 23 thrust upwards by the recording disc 101 so as to be rotated beyond the above-mentioned neutral rotational position so as to be returned to its initial position.
With the present disc table, not only the recording disc 101 housed within the cartridge main body 104, but also the recording disc 101 not housed within the cartridge main body 104, may be set with correct centering on the disc setting surface 3, as hereinabove described. The number of the clamping members may be at least two or four or more in stead of three in the above described embodiments.
A disc table of a fourth embodiment according to the present invention is hereinafter explained.
In the present embodiment, the centering segments 12 may be mounted in a stressed state, that is in a state of being resiliently flexed inwardly towards the center axis of the fitting member 4, as shown in FIG. 16, instead of in a natural or stress-free state, that is in a state free from resilient flexing. In this case, the centering segments 12 have their distal ends intruded into the cut-outs 10 in the inwardly resiliently flexed or stressed state so that the distal ends are caused to bear against the inner wall sections of the cut-outs 10. That is, with the present disc table, the inner wall sections of the cut-outs 10 act as resetting controlling sections for controlling the resetting of the centering segments 12 to their natural state.
When the recording disc 101 is set on the disc setting surface 3 of the table section 2, as shown by arrow C in FIG. 16, the centering segments 12 are thrust and resiliently flexed by the inner rim of the center aperture 102 of the recording disc 101, while thrusting the inner rim of the center aperture 102, as shown in FIG. 17. At this time, each of the centering segments 12 has its distal end resiliently biased from the position of being caused to bear against the inner wall section of the cut-out 10 to the position of being caused to bear against the inner rim of the center aperture 102 of the recording disc 101, as shown by arrow J in FIG. 17.
Since the centering segments 12 are not biased from their unstressed state, it is possible for these centering segments 12 to exhibit a sufficient thrusting force corresponding to the displacement from the unstressed state, which thrusting force may be exerted on the inner rim of the center aperture 102 of the recording disc 101, even although the segments 12 deemed as spring plates are of a small spring constant. Consequently, the recording disc 101 may be correctly centered by these centering segments 12. Besides, in the initial state in which the recording disc 101 is not loaded, the centering segments 12 are controlled in their positions by the inner wall sections of the cut-outs 10 and hence positioned with great accuracy.
A disc table of a fifth embodiment according to the present invention is hereinafter explained.
By the way, the centering means in the disc table of the present fifth embodiment is not limited to plural centering segments in the form of plural spring plates, as those shown in the above-described embodiments, but may consist in plural centering segments 12 connected to an annular section of the centering ring 11 via hinges 12a, and an elastic member 12b, as shown in FIG. 18.
The centering segments 12 are pawl-shaped lugs disposed at equiangular intervals in register with the cut-outs 10 for extending radially relative to the annular section of the centering ring 1. These centering segments are intruded into the cut-outs 10. Similarly to the centering segments 12 of the preceding embodiments, each of the centering segments of the present embodiment has only its distal end projected out of the fitting member 4 at the proximal part of the fitting member 4. Each hinge 12a is formed at the proximal side of each centering segment 12 by locally reducing the thickness of the centering segment 12. The centering segments 12 may be biased in a direction of being protruded out of or being receded inwardly of the fitting member 4 by resilient flexure of the hinge 12a. The elastic member 12b is formed substantially as an annulus from an elastic material, such as butyl rubber, and is interposed between the centering segments 12 and the annular section of the centering ring 11. That is, the elastic member 12 is fitted to the outer side of the annular section of the centering ring 11 and is disposed inwardly of the centering segments 12.
When the recording disc 101 is set on the disc setting surface 3 of the table section 2 of the disc table, as shown by arrow C in FIG. 18, the centering segments 12 are displaced by being thrust by the inner rim of the centering aperture 102 to compress the elastic member 12b, as shown by arrow K in FIG. 19, with the inner rim of the center aperture 102 in turn being thrust by the elastic recoil of the elastic member 12b.
Since the displacement of the centering segments 12 at this time is not an elastic displacement, the centering segments 12 are not susceptible to creep even after repeated displacement and hence exhibit excellent durability. Since the thrusting force against the inner rim of the center aperture 102 of the recording disc 101 is obtained by the force of elastic recoiling of the elastic member 12b, the thrusting force may be increased to a sufficient level by suitably selecting the material and/or the shape of the elastic member 12b. Consequently, the recording disc 101 may be satisfactorily centered by the centering segments 12.
A disc table of the sixth embodiment according to the present invention and the method for producing the disc table according to the present invention are hereinafter explained.
The disc table of the sixth embodiment may be constituted using a centering ring 11 formed of a metallic spring plate material, as shown in FIGS. 20 to 22, 24 and 25.
Similarly to the disc tables of the preceding embodiments, the present disc table is also provided with a table section 2 supported by being fitted on the outer surface of the driving shaft 1 of the spindle motor 5. The table section 2 is formed substantially as a disc from a synthetic resin and has a center through-hole 8 engaged by the driving shaft 1. The table section 2 has a perimetral portion of its upper surface as a disc setting surface 3 for setting the recording disc 101 thereon.
Referring to FIG. 21, the spindle motor 5 for rotationally driving the disc table is mainly made up of an outer casing 35, a bearing 34 supported by the outer casing 35 for rotatably supporting the driving shaft, annular magnet 32, 32 mounted on the driving shaft 1 via a magnet supporting member 33 and a coil base plate mounted facing the magnets 32, 32 within the outer casing 35. The spindle motor 5 is supported by having the outer casing 35 mounted on the lower surface of the chassis 6 so that the driving shaft 1 is protruded above the chassis 6 via a through-hole bored in the chassis 6.
A fitting member 4 is projectedly formed at the center of the upper surface of the table section 2, as in the disc tables of the preceding embodiments. That is, the fitting member 4 is formed with the table section 2 in substantially a conical shape and has an outside diameter large enough to be engaged in the center aperture 102 of the recording disc 101. The distal part of the fitting member 4 is a guide section for capturing the recording disc 101. The part of the fitting member 4 lying close to the disc setting surface 3 is a columnar section 4b having an outside diameter substantially equal to the inside diameter of the center aperture 102 of the recording disc 101.
The distal end face of the fitting member 4 has a magnet mounting recess 13 which is formed as an annular groove concentric with the fitting member 4. Within this magnet mounting recess 13 is mounted an annular magnet 9 acting as thrusting and supporting means. The magnet 9 is used for attracting a magnetic plate 104 mounted at the mid-part of the recording disc 101 for closing the center aperture 102, as shown in FIGS. 24 and 25. A magnetic yoke formed of a high permeability material may be provided on the lower surface of the magnet 9, that is between the magnet 9 and the fitting member 4.
The fitting member 4 has plural cut-outs 10 in communication with the magnet mounting recess 13. These cut-outs 10 are formed outwardly of the magnet mounting recess 13 for extending radially from the magnet mounting recess 13 through the proximal side of the fitting member 4 as far as a disc-shaped part of the table section 1. These cut-outs 10 are provided at three points at an angular interval of 120° relative to each other.
A centering ring 11, constituting centering means for aligning the center of rotation of the recording disc 101 with the axis of the disc table, is mounted on the lower surface of the table section 2 so that the centering segments 12, 12, 12 functioning as the centering members are located within the cut-outs 10, 10, 10 of the fitting member 4. The centering ring 11 is formed as one from a plate-shaped metallic spring material by punching and press working. The centering ring 11 comprises a substantially disc-shaped base section 26, three upstanding supporting projections 29 provided on the perimetral portions of the base section 26 and three centering segments 12 extending outwardly from the distal ends of these supporting projections 29, as shown in FIG. 22.
The base section 26 has a central through-hole 27 having a diameter sufficiently larger than the outside diameter of the driving shaft 1.
The supporting projections 29, 29, 29 are formed upright around the perimeter of the base section 26 at an equiangular interval of 120° relative to one another. These supporting projections 29 are formed by bending three tongues extending outwardly from the outer perimeter of the base section 26 by press working. These supporting projections 29 are formed with drawn parts 30, 30, 30 extending outwards from the base section 26. These drawn parts are formed by drawing so that part of the spring material of the centering ring 11 is bent to form rib-shaped projections extending from the supporting projections 29 and the base section 26. These drawn parts 30 prevent the supporting projections 29 from being tilted with respect to the base section 26.
The proximal ends of the centering segments 12 are formed as continuation of the distal ends of the supporting projections 29. These centering segments 12 are positioned outwardly of the supporting projections 29, that is at a distance from the base section 26, and are inclined downwardly from the distal ends of the supporting projections 29. The distal end of each of the centering segments 12 is formed with a pair of bent tabs 31,31. These tabs 31, 31 are formed as tongues on the opposite lateral sides of the centering segments 12 and arcuately bent towards the center of the base section 26. These centering segments 12 and the tabs 31, 31 of each of these segments are formed by press-working the parts extended horizontally from the supporting projections 29.
The perimetral part of the base section 26 is formed with three equiangular cut-outs 28 for accommodating an adhesive which are disposed between the supporting projections 29. These cut-outs 28 are substantially semicircular in contour.
The centering segments 12 are intruded into the cut-outs 10 by the base section 26 being mounted on the lower surface of the table section 2. The base section 26 is mounted on the table section 2 by applying an adhesive, such as a so-called UV curable resin, in the cut-outs 28 for adhesive, while the major surface of the base section 26 is kept in pressure contact with the lower surface of the table section 2. The distal ends of the supporting projections 29 are positioned at this time around the perimeter of the magnet 9 and are spaced apart from the magnet 9 and the fitting member 4. These centering segments 12 may be biased resiliently.
With the centering ring 11 mounted on the table section 2, each of the centering segments 12 has its proximal end positioned in the vicinity of the distal end face of the fitting member 4, and is supported with a tilt relative to the disc setting surface 3, so that part of the distal end thereof is projected outwardly from the cut-out 10, that is in the direction of the perimeter of the fitting member 4, as shown in FIG. 24. The distal end of each of these centering segments 12 may be projected beyond or receded with respect to the peripheral surface of the fitting member 4 by elastic deformation of the proximal part of each of the segments 12. The distal end of each of these segments 12 is disposed below the disc setting surface 3 so as to be caused to bear against the inner wall of the cut-out 10. The centering segments 12 are resiliently biased at this time closer to the base section 26 than when the segments 12 are in the stress-free state.
The method for producing the disc table having the centering ring 11 formed of the spring plate material is hereinafter explained in detail. For producing the disc table, a positioning jig 50 shown in FIG. 23 is employed. The positioning jig 50 has a block-shaped main body having a recessed positioning hole 51. A reference shaft 53 having a outside diameter substantially equal to that of the driving shaft 1 of the spindle motor 5 is mounted upright on the bottom surface of the positioning hole 51. Part of the inner wall of the positioning hole 51 is formed as wall sections 52, 52, 52 for abutment with the centering segments 12 in register with the cut-outs 10, 10, 10. The portions of the inner wall other than the wall sections 52, 52, 52 are enlarged in diameter radially outwardly of the wall sections 52, 52, 52. These wall sections 52, 52, 52 are designed to form a part of a cylindrical surface coaxial with the reference shaft 53. The diameter of the cylindrical surface enveloping the wall sections 52, shown by arrows L in FIG. 23, is selected to be slightly smaller than the inside diameter of the center aperture 102 of the recording disc 101, and is typically on an order of 10.98 to 10.99 mm for the inside diameter of the center aperture 102.
In the method for producing the disc table according to the present invention, the reference shaft 52 is fitted into the fitting thorough-hole 8 for the table section 2 bored in the fitting member 8, as shown in FIG. 23. At this time, the reference shaft 53 is engaged in the fitting through-hole 8, as the fitting member 4 is faced by the positioning hole 51 so that the fitting member 4 may be fitted into the positioning hole 51. At this time, the cut-outs 10 are in register with the wall sections 52.
The centering ring 11 is then set on the table section 2 loaded on the positioning jig 50. The centering ring 11 has its base section 26 set on the lower surface of the table section 2 so that the centering segments 12 are introduced into the cut-outs 10. Each of the centering segments 12 has its distal end abutted against the wall sections 52. Since the centering segments 12 are resiliently biased towards the base section 26, the centering segments 12 thrust the wall sections 52 by their resiliency. Thus, under the elastic recoiling force of the centering segments 12, the centering ring 11 is moved to and halted at a position at which the resilient recoiling forces of the centering segments 12 are in equilibrium, that is a position at which the resilient recoiling forces of the centering segments 12 become equal to one an another. Meanwhile, since the supporting projections 29, the magnet 9 and the fitting member 4 are spaced apart from one another, there is no risk of obstruction of the movement of centering ring 11 under the resilient recoiling force of the centering segments 12.
The centering ring 11 is fixedly mounted on the fitting member 4 by being bonded to the lower surface of the table section 2 by UV resin or thermoplastic adhesive 32 at the position at which the resilient recoiling forces of the centering segments 12 counterbalance one another. For bonding the centering ring 11 to the table section 2 by the adhesive 32, the adhesive in a fluid state is dripped into the cut-outs 28 so that the adhesive 32 is in contact with both the centering ring 11 and the table section 2, the adhesive 12 being then allowed to be cured in situ. The adhesive 32 is cured by irradiation of UV rays by heating.
The table section 2 is then dismounted from the positioning jig 50 along with the centering ring 11. The centering segments 12 of the centering ring 11, thus mounted on the table section 2, are designed to produce outwardly directed resilient recoiling forces of equal magnitude when the segments are deflected as far as a circumference of a circle coaxial as the fitting hole 8 and having a diameter substantially equal to the diameter of the recording disc 101.
For setting and loading the recording disc 101 on the disc setting surface 3 of the disc table having the centering ring 11 formed of the spring plate material, the recording disc 101 is fitted on the fitting member 4 so that the rim of the center aperture 102 of the disc 101 is engaged with the fitting member 4, as shown by arrow C in FIG. 24.
When the recording disc 101 is moved towards the proximal side of the fitting member 4, the inner rim of the center aperture 102 is caused to bear against the centering segments 12, as shown in FIG. 25. The inner rim of the center aperture 102 is moved towards the proximal side of the fitting member 4, as it causes the centering segments 12 to be resiliently deformed and intruded into the cut-outs 10. At this time, each of the centering segments 12 is resiliently biased from the position at which it has its distal end abutted against the inner rim of the cut-out 10 to a position at which the centering segment has its distal end abutted against the center aperture 102 of the recording disc 101, as shown by arrow J in FIG. 25. On the other hand, the inner rim of the center aperture 102 is thrust outwards under the resilient restoring force of the centering segments 12.
When the recording disc 101 is fitted over the columnar section 4b of the fitting member 4 at the center aperture 102 thereof, with the portion of the recording disc 101 neighboring to the center aperture 102 being set on the disc setting surface 3, as shown in FIG. 25, the inner peripheral portion of the center aperture 102 is thrust against the centering segments 12 to effect a centering operation of aligning the center of the center aperture 102 with the axis of the fitting member 4.
At this time, the magnet 9 attracts the magnetic plate 104 mounted on the recording disc 101 for thrusting and supporting the recording disc 101 with respect to the disc setting surface 3.
When the recording disc 101 is loaded in position on the table section 2, and the driving shaft 1 is run in rotation by the spindle motor 5, the recording disc 101 is rotated in unison with the table section 2. The information signals are recorded on or reproduced from the signal recording layer of the recording disc 101 by the optical head device or the magnetic head device.
Meanwhile, for achieving optimum centering of the recording disc 101 by the centering segments 12 even after setting the disc 101 on the disc setting surface 3, it is necessary for the centering segments 12 to thrust the inner rim of the center aperture 102 of the recording disc 101 with a sufficient force. On the other hand, if an excess force is applied by the centering segments 12 against the inner rim of the center aperture 102, and an insufficient force of magnetic attraction is applied by the magnet 9 to the magnetic plate 104, the recording disc 101 cannot be moved to a position of abutment with respect to the disc setting surface 3. In this consideration, the spring constant k 0 of the centering segments 12 is selected to be not less than the minimum value k 1 of the spring constant capable of sufficiently correcting an offset of the recording disc 101 with respect to the fitting member 4 and not larger than the maximum value of the spring constant capable of shifting the recording disc 101 to the position of abutting the recording disc 101 against the disc setting surface 3 under the force of magnetic attraction by the magnet 9 of the magnetic plate 104.
It is now assumed that the spring constant of the centering segments 12 is k, the displacement of the centering segments 12 is Δx, the frictional coefficient between the centering segments 12 and the inner rim of the recording disc 101 is μ 1 and the frictional coefficient between the recording disc 101 and the disc setting surface 3 is μ 2 . When the inner rim of the center aperture 102 is caused to bear against the centering segments 12, a force of magnetic attraction F exerted by the magnet 9 on the magnetic plate 104 as indicated by arrow F in FIG. 25 and a reactive force kΔx exerted by the centering segment 12 on the inner rim of the center aperture 102 in a perpendicular direction act for each of the centering segment 12. It is assumed that the angle of tilt of the portion of the centering segment 12 abutted against the inner rim of the center aperture 102 of the recording disc 101 is indicated as an angle θ from the horizontal, as indicated by arrow θ in FIG. 25. Assuming that three centering segments 12 are provided, the formula
F=μ.sub.1 k.sub.2 Δx sin θ+k.sub.2 Δx cos θ(3)
holds for the maximum value k 2 , so that
k.sub.2 =F/{Δx(μ.sub.1 sin θ+cos θ)} (4)
and, since k 0 <k 2 , the formula
k.sub.0 <F/{Δx(μ.sub.1 sin θ+cos θ)} (5)
holds.
As for the minimum value k 1 , if an offset of the recording disc 101 with respect to the fitting member 4 is indicated by D and a force of shifting the recording disc 101 towards the center position is indicated by C, the force C is given by
C=2k.sub.1 (Δx+D cos 60°sin θ) sin θcos 60°-k.sub.1 (Δx-D sin θ) sin θ=(3/2)k.sub.1 D sin.sup.2 θ (6)
while a force of resistance R against the movement of the recording disc 101 is given by
R=μ.sub.2 (3F-k.sub.1 Δx cos θ (7)
In order for the recording disc 101 to be moved, it is necessary for the force of movement C to be larger than the force of resistance R. Consequently, from
(3/2)k.sub.1 D sin.sup.2 θ>μ.sub.2 (3F-k.sub.1 Δx cos θ), the formula k.sub.1 =6μ.sub.2 F/(3D sin.sup.2 θ+2μ.sub.2 Δx cos θ) (8)
holds. Since k 1 <k 0 , the formulas
k.sub.0 >6μ.sub.2 F/(3D sin.sup.2 θ+2μ.sub.2 Δx cos θ) (9)
holds.
It is observed that, since the centering segments 12 are formed of a metallic spring plate material, the spring constant of the centering segments 12 set in this manner may be substantially five times as large as the spring constant when the centering segments 12 are formed of a spring plate material of synthetic resin of the same thickness as that of the metallic spring plate material.
With the disc table, constituted with the centering ring 11 of the spring material, the recording disc 101 may be centered satisfactorily by the centering segments 12. Besides, since the distal ends of the centering segments 12 are caused to bear against the inner wall sections of the cut-outs 10, the thrusting force exerted on the inner rim of the center aperture 102 undergoes less fluctuations by an error possibly present in the spring constants. In addition, in the initial state in which the recording disc 101 is not loaded in position, the centering segments 12 are controlled in their positions by the inner wall sections of the cut-outs 10, so that the centering segments 12 may be positioned with great accuracy.
Besides, since the centering segments 12 are formed of a metallic material, they are excellent in creep resistance and exhibit superior durability under high temperature environment. Furthermore, these centering segments 12 may be fabricated with a precise spring constant as compared to the case wherein the segments 12 are fabricated from a synthetic resin.
Each centering segment 12 is provided with the tabs 31, 31, and has the portion abutted against the inner rim of the center aperture 102 of the recording disc 101 bent substantially arcuately towards the base section 26, so that it becomes possible to prevent a damage from being done to the inner rim of the center aperture 102 as well as to assure smooth movement of the recording disc 101 towards the disc setting surface 3.
A disc table of a seventh embodiment according to the present invention is explained.
When the disc table of the seventh embodiment according to the present invention is fabricated using the centering ring 11 of a spring material, as described above, the distal ends of the centering segments 12 may be provided with pads 34 of synthetic material, as shown in FIG. 26, instead of with the bent tabs 31, 31. These pads 34 may be provided on the centering segments 12 by a so-called outsert molding method. These pads 134 are provided at the portions of the centering segments 12 abutted against the inner rim of the centering aperture 102, so that, in the initial state in which the recording disc 101 is not loaded in position, the pads 134 are projected outwardly of the fitting member 4.
With the present disc table, it is similarly possible t to prevent damages from being inflicted by the centering segments 12 on the inner rim of the center aperture 102 of the recording disc 101, as well as to assure smooth movement of the recording disc 101 towards the disc setting surface 3. | A disc table employed in a disc recording/reproducing apparatus has, as a recording medium, a recording disc, such as an optical disc or a magneto-optical disc, on which information signals are pre-recorded or are to be recorded. The disc table includes a fitting member fitted from its distal end into a circular center aperture of the recording disc, a table section which is integrated to the fitting member at a proximal side of the fitting member and on which a rim portion around the center aperture of the disc is set, a thrusting and supporting unit for thrusting and supporting the recording disc with respect to the table section, and a centering unit provided at a proximal side of the fitting member and adapted for thrusting the rim portion around the center aperture of the recording disc for aligning the center of rotation of the recording disc with the center of rotation of the fitting member. The fitting member is gradually tapered towards its distal end where the fitting member is provided with a guide slidingly contacted with the inner rim of the center aperture of the recording disc for guiding the recording disc towards the center of rotation of the fitting member. The recording disc may be positively centered to enable stable rotation of the recording disc while realizing a simplified thin type construction. | 6 |
This application claims benefit of provisional appln. Ser. No. 60/153,798 filed Sep. 14, 1999.
FIELD OF THE INVENTION
The invention relates to a system for depositing cheese on a pizza crust and, more particularly, to a system for forming a bead of cheese on the periphery of a crust for forming a stuffed rim thereof
BACKGROUND OF THE INVENTION
Currently, precooked frozen pizzas that have a rim stuffed with cheese are made by manually placing strips of string mozzarella cheese about the periphery of the crust with the edge of the crust folded over thereon. As is apparent, the manual labor required with the making of the stuffed rims is labor intensive and limits production rates.
Another shortcoming of the above-described process is in the use of string cheese. First, string cheese is a relatively expensive raw material due in part to the fact that it is a perishable item which requires that it be manufactured when fresh. Another problem is that string mozzarella cheese typically is not manufactured in large quantities because of its perishable nature, e.g. shelf life of approximately 14 days. On the other hand, IQF (Individually Quick Frozen) shreds of mozzarella cheese are generally lower in price because they are frozen which allows the manufacturer to make large quantities of the cheese when their raw material costs therefor are low and slow down or temporarily cease manufacture when raw materials are at higher costs.
Accordingly, there is a need for an improved system and method for producing pizza crusts having cheese filled rims. Further, the system and process should be able to produce large quantities of the stuffed crusts with high production throughput while minimizing costs associated therewith.
SUMMARY OF THE INVENTION
In accordance with the invention, a system and method are provided for forming IQF shreds of mozzarella cheese into a bead form and depositing it on the periphery of a crust for a pizza. The invention heats and extrudes the IQF shreds with the extrudable mass formed into a bead for placement on the crust about the periphery thereof. The body of the cheese in its bead form lacks the desired stringiness characteristic of string mozzarella cheese. This stretchiness or string characteristic is one feature that makes string mozzarella cheese particularly well-suited for use with pizza. However, after the pizza crust including the bead of cheese is baked, it has been found that the cheese reconstitutes to provide a stringiness characteristic thereto similar to that provided by string mozzarella cheese.
In one form of the invention, a system is provided for forming a paste-like bead of cheese from small frozen shreds of cheese and depositing the bead on a pizza crust. The system includes a heating apparatus having a chamber for receiving the frozen cheese shreds and a tempering portion for raising the temperature of the cheese shreds for further processing. An extrusion apparatus is provided for forming the cheese shreds into an extrudable mass. The extrusion apparatus includes an advancing mechanism which drives the mass of cheese for being deposited onto the pizza crust. An extrusion head is provided for the extrusion apparatus and has at least one outlet from which the cheese exits to form and deposit the bead on the crust. Accordingly, the present system allows for use of IQF mozzarella shreds and obviates the manual labor of having workers manually place the mozzarella strings on the crust about its periphery, thus reducing raw material and labor costs associated with the process of forming cheese stuffed rims for frozen pizzas.
In another aspect of the invention, an automated method of making pizza crusts having a rim full of cheese is provided. The automated method includes providing a crust having a peripheral region thereabout, heating small shreds of frozen mozzarella cheese, extruding the heated mozzarella cheese to a smooth paste-like body of cheese in a bead form with the body lacking stringiness, depositing the bead of cheese about the peripheral region of the crust, folding an edge of the crust over the bead of cheese, and baking the crust with the mozzarella cheese bead reconstituting so that the body has stringiness. The method uses IQF mozzarella shreds formed into a paste so it can be laid down as a bead about the crust with the body of the bead lacking the stringiness quality desired for pizza cheeses. However, after cooking, the mozzarella in the bead reconstitutes so that it has string similar to the more expensive string mozzarella cheese.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of IQF shreds of mozzarella cheese;
FIG. 2 is a view of string mozzarella cheese and manual placement thereof on pizza crusts;
FIG. 3 is a perspective view of a ribbon blender;
FIG. 4 is a perspective view of the ribbon blender of FIG. 3 with IQF cheese shreds therein;
FIG. 5 is a perspective view of an extruder including a hopper and extruder housing for receiving the IQF shreds of cheese after processing by the ribbon blender;
FIG. 6 is a perspective view of a passageway of the extruder including rotary drives for extruder screws shown in phantom;
FIG. 7 is a perspective view of a disassembled extrusion head including rotary valve members and control linkages therefor;
FIG. 8 is a perspective view similar to FIG. 7 showing the extrusion head assembled;
FIG. 9 is a perspective view of the assembled extrusion head similar to FIG. 8;
FIG. 10 is a perspective view of a crust forming pan for supporting six crusts for processing;
FIG. 11 is a perspective view of dough formed into crusts in the pan;
FIG. 12 is a perspective view of the extrusion heads over the crusts;
FIG. 13 is a perspective view of the extrusion heads depositing a bead of cheese on the crusts;
FIG. 14 is a perspective view of the crusts having beads of cheese thereon;
FIG. 15 is a perspective view of one of the beads of cheese on a single one of the crusts;
FIG. 16 is a perspective view of the upper flanged portion of the crusts cut therefrom;
FIG. 17 is a perspective view of the upstanding edge wall folded over the cheese bead;
FIG. 18 is a perspective view of the fold over mechanism for folding the crust wall over the cheese bead;
FIG. 19 is a perspective view of the crusts with the folded over wall crimped down over the cheese bead;
FIG. 20 is a perspective view of the crusts being dropped from the crust forming pan for further processing; and
FIG. 21 is a perspective view of the crust in a support pan therefor with the rims folded over the beaded cheese.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a system and method that allows for the use of IQF shreds 10 (FIG. 1) of mozzarella cheese such as LMPS mozzarella to be used as the starting material in making a stuffed pizza crust 12 , and in particular, a stuffed rim 14 thereof. The use of the small frozen IQF shreds, e.g., quarter inch by quarter inch blocks, is advantageous over the prior use of string mozzarella cheese 16 (FIG. 2) in terms of costs and because frozen IQF shreds 10 can maintain their melt characteristics for long periods of time and without experiencing the negative effects of enzyme modification before the cheese ages. In addition, the present system and method as described hereinafter provides for automated depositing of the bead 18 of mozzarella cheese having a smooth paste-like consistency on the crust thus avoiding the manual labor required for having workers manually place the string cheese 16 about the crust 12 for making the stuffed rims 14 thereof.
Initially, the IQF shreds 10 are fed into a heating apparatus 20 in the form of a ribbon blender, as shown in FIGS. 3 and 4. The ribbon blender 20 includes a chamber 22 having a pair of laterally spaced drive shafts 24 and 26 that are driven for rotation in opposite directions therein. Two helical or auger type ribbons 28 and 30 are mounted to the drive shaft so that rotation of the shafts 24 and 26 causes the IQF shreds to travel longitudinally in the chamber 22 first in one direction as indicated by arrow 32 as driven by helical ribbon 28 and then in the opposite direction indicated by arrow 34 as driven by helical ribbon 30 .
The IQF cheese shreds 10 are tempered or heated in the chamber 22 via a heating portion of the ribbon blender 20 in the form of a hot water jacket 36 that is disposed about the chamber 22 . As the IQF shreds 10 traverse the length of the chamber 22 in both directions 32 and 34 , the dwell time in the chamber 22 is maximized for heat transfer from the hot water jacket 36 to raise the temperature of the IQF mozzarella shreds 10 .
After the IQF mozzarella shreds 10 have been tempered or heated in the ribbon blender 20 , they are transferred to an extrusion apparatus 38 as shown in FIG. 5 .
The extrusion apparatus 38 includes a hopper 40 which funnels and feeds the tempered IQF mozzarella shreds 10 into a passageway 42 in the housing 43 of the extruder 38 below the hopper 10 , as shown in FIG. 6 . The passageway 42 redirects the tempered IQF mozzarella shreds 10 in a generally horizontal direction via an advancing mechanism, generally designated 44 . The advancing mechanism 44 includes a pair of rotatable couplings 46 and 48 for rotating extruder screws, 50 and 52 , shown in phantom.
The screws 50 and 52 extend parallel to each other and are rotated in the same direction so that the IQF mozzarella shreds 10 are advanced from one end of the passageway 42 downstream to extrusion heads 54 . The screws 46 and 48 are sized relative to the passageway 42 and rotated at a speed such that the IQF mozzarella shreds 10 are worked into an extrudable mass. It is important that the extrusion be tailored so that the working of the IQF mozzarella shreds 10 does not release oil therefrom and generate oiling off problems, as are known to be undesirable in the pizza making art. It has been found that generating a pressure of approximately 300 to 400 psi in the extruder 38 is sufficient to create an extrudable mass of the cheese without generating oiling off problems. To this end, a control is provided which senses a maximum pressure that cannot be exceeded before the control will act to shut off the drive for the extruder screws 50 and 52 .
FIGS. 7-9 depict an extrusion head 54 which communicates with the extruder passageway 42 . In the illustrated and preferred form, the extruder head 54 has an inverted V-shape including an inlet 56 from which a pair of tubular arms 58 and 60 are branched having respective outlets 62 and 64 at ends distal from the inlet 56 .
The extrusion heads 54 are preferably mounted so that their inlets 56 are disposed above the center of the pizza crust 12 so that rotating the extrusion head 54 via a drive deposits the bead 18 having a smooth, paste-like consistency about a peripheral region 66 of the crust 12 . As noted, the body of cheese in the bead form lacks the desired stringiness characteristic for pizza cheese. The distance between the outlets 62 and 64 substantially matches that of the diameter of the predetermined position on the crust peripheral region 66 at which the substantially circular bead 18 is to be deposited. Referring to FIGS. 12-14, the extrusion head 54 is rotatably coupled to the extruder 38 so that the head 54 can be rotated 180 degrees in one direction while it deposits the bead 18 with each arm 58 and 60 depositing one half of the circular pattern for the bead 18 , and then being rotated back with the outlets 62 and 64 closed to its starting position for the next crust 12 . As shown in FIG. 11, a crust forming pan 68 is provided with six openings 70 in which the pizza crust is initially formed. Accordingly, in the preferred and illustrated form six extrusion heads 54 are coupled to the extruder 38 and are simultaneously rotated by a drive including a motor and a belt for rotating the rotatable couplings between the extrusion heads 56 and the extruder 38 . In this fashion, extremely high production rates can be obtained with the system and method of the present invention. In this regard, approximately one-hundred crusts per minute having beads 18 of mozzarella cheese deposited thereon can be made.
As can be seen in FIGS. 7-9, the ends of the arms 58 and 60 distal from the inlet 56 include respective valve housings 72 and 74 having cylindrical throughbores 76 and 78 that are oriented transverse to the length of the arms 58 and 60 . The bores 76 and 78 are adapted to receive rotary valve members 80 and 82 therein. The valve members 80 and 82 have a cylindrical body with a T-shaped cutout extending transversely therethough. More specifically, the T-shaped cutout includes a slotted inlet end 84 from which a central passageway 86 extends to an outlet end 88 . Accordingly, the slotted inlet end 84 extends for a greater extent along the circumference of the cylindrical body of the rotary valve members 80 and 82 than the outlet end 88 thereof. In this manner, as the rotary valve members 80 and 82 are rotated between open and closed positions in their respective housings 72 and 74 as will be described more fully hereinafter, the elongated or slotted inlet end 84 stays in communication with the passageway through the tubular arms 58 and 60 and thus the passageway 42 of the extruder 38 whether in the opened or closed positions. This provides advantages in terms of the starting and stopping of the depositing of the bead 18 as the slug of cheese in the rotary valve members 80 and 82 remains, in effect, connected to the extrudable mass in the head 54 and extruder 38 so that discontinuities or other deformities that may be created in the circular pattern of the bead 18 at the starting and stopping points of the depositing of the bead 18 by the extruder head arms 58 and 60 are minimized.
The cylindrical rotary valve members 80 and 82 are sealed in the bores 76 and 78 of their respective housing 72 and 74 by way of annular O-ring seals 90 mounted about either end thereof. The valve members 80 and 82 are provided with an extension portion 130 which projects out from the housing, as best seen in FIGS. 8 and 9. The extension portion 130 has an annular groove 132 formed thereabout and into which a hook member 134 pivotally mounted to each of the housings 72 and 74 is received to prevent the valve members 80 and 82 from sliding laterally out from the housing bores 76 and 78 .
For shifting the rotary valve members 80 and 82 between their opened and closed positions, control linkages, generally designated 94 are provided. The linkages 94 can include a power cylinder such as pneumatic cylinder 96 having a piston rod 98 connected at its distal end to a link plate 100 . The plate 100 is attached to the piston rod 98 at one end and to the rotary valve member 80 at its other end so that as the piston rod 98 is extended and retracted by operation of pressurized air through lines 102 and 104 , the plate 100 will rotate the valve member 80 so that its outlet end 88 is in registry with the outlet 62 of the valve housing 72 with the valve member 80 in its open position or rotated so that the valve member outlet end 88 is sealed by a wall of the housing 72 in its closed position. A rod 106 is attached at one of its ends to the plate 100 intermediate the attachments of the plate 100 to the piston rod 98 and rotary valve member 80 with the rod 106 attached at its other end to a link plate 108 which, in turn, is attached to the other rotary valve member 82 . In this manner, extension and retraction of the piston rod 98 rotates both the valve members 80 and 82 in a synchronized manner so that both are opened and closed at the same time.
As previously mentioned, the preferred crust forming pan 68 has six openings 70 having generally vertical annular walls 110 bounding the openings 70 with slots 112 spaced equidistantly about the circumference of the walls 110 , as best seen in FIG. 10 . Dough is tamped into the openings 70 and supported by a bottom pan plate 113 therein to form initial crusts having an upstanding edge wall 114 about the peripheral region 66 of the crust and an upper flanged portion 116 projecting radially out from the top of the wall 114 . The extrusion heads 54 deposit the beads 18 in a substantially circular pattern about the peripheral region 66 generally between the bottom of the crust 12 and the edge wall 114 , as best seen in FIGS. 12-15.
Thereafter, the upper flange portion 116 is cut so as to be severed from the remainder of the crust 12 , as shown in FIG. 16 . The upstanding edge wall 114 is then folded over the bead 18 of mozzarella cheese, as can be seen in FIG. 17 . For this purpose, several pivotal knock-down members 118 associated with each of the slots 112 is mounted to a platen 120 . When the crust arrives at the fold-over station of FIGS. 17 and 18, the platen 120 is raised and the knock-down members 118 are pivoted through their slots 112 to engage the outer side of the upstanding edge wall 114 for folding it down over the circular bead 18 of cheese on the crust peripheral region 66 .
After the edge wall 114 has been folded over as described, it is crimped (FIG. 19) to form the cheese stuffed rim 14 of the pizza crust 12 . The support plate 113 for the crust 12 then drops away from the crust forming pan 68 (FIG. 20) for further processing, such as proofing and baking.
As has been stated, it has been found that after the crust 12 including the cheese bead 18 has been baked, the body of the cheese in the bead reconstitutes with the desired stringiness characteristic. It had been assumed that the mozzarella cheese after working as through an extrusion process would not obtain this quality and instead it was expected that cheese melts and/or processed cheeses would have to be used in the present application. However, it has been found that with careful design and selection of the equipment and the operating conditions thereof as specified herein, the cheese stuffed rim 12 can be formed by an automated process and using lower cost IQF shreds 10 as the starting material while achieving commercially satisfactory results in terms of the texture and stringiness characteristics of the cheese.
While there have been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention. | A system and method are provided for forming IQF shreds of mozzarella cheese into a bead form and depositing the bead on the periphery of a pizza crust for forming a pizza with a cheese stuffed rim. The IQF shreds are heated and then extruded to form the bead placed on the crust periphery via a high speed extrusion head. Heating and extrusion techniques are disclosed that work the IQF shreds into an extrudable mass or paste that, although lacking the desired stringiness quality, reconstitutes upon baking such that stringiness comparable to more expensive string mozzarella cheese is achieved. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of and claims the benefit of and priority to U.S. patent application Ser. No. 12/486,819 filed on Jun. 18, 2009 now abandoned by Heinrich et al., which claims the benefit of and priority to U.S. Provisional Application No. 61/082,852 filed on Jul. 23, 2008, the entire contents of each of these applications are herein incorporated by reference.
BACKGROUND
1. Technical Field
The present disclosure relates to a surgical staple for use in surgical procedures. More particularly, the present disclosure relates to a surgical staple and a staple assembly configured to accommodate various thicknesses of tissue by assuming a box configuration upon formation through tissue. The present disclosure also relates to a method of stapling tissues of various thicknesses with a single, uniform size staple.
2. Background of Related Art
During various surgical procedures it is often necessary to secure one or more tissue sections together or to secure auxiliary structures such as, for example, mesh, buttress material, etc. to tissue. This is typically accomplished by driving a conventional staple, having a backspan and a pair of legs extending from the backspan, through the tissue and/or through the auxiliary structure. Once the conventional staple has been driven through the tissue, the ends of the legs are engaged with an anvil of the type typically having a pair of arcuate anvil pockets. This engagement causes the ends of the legs to be bent or recurved back towards the tissue to secure the tissue sections together and/or to secure the auxiliary material to the tissue. These bent or recurved portions of the staple legs are the tissue clenching portions of the legs.
When attempting to secure relatively thick sections of tissue together or auxiliary material to a relatively thick tissue section, the sizing of the conventional staple is critical to ensure sufficient leg lengths to traverse the tissue. Insufficient leg lengths will result in incomplete stapling of the tissue.
Further, when attempting to secure relatively thin sections of tissue together, or auxiliary material to the relatively thin tissue section, the sizing of the conventional staple is selected to ensure that there is not an excess of leg length. Excess leg length may result in the clenching portions of the legs projecting substantially away from the tissue as well as causing the ends of the leg to recurve back into and penetrate the tissue.
Therefore, it is desirable to provide a staple having a leg length sufficient for various tissue thicknesses expected to be encountered. It is further desirable to provide a box shaped staple capable of being formed such that the clenching portions of the legs lie parallel to and flush against the tissue to be secured. It is still further desirable to provide a box staple assembly incorporating a staple plate to increase the bearing area of the staple against the tissue and shield the tissue from the ends of the staple legs.
SUMMARY
There is disclosed a box staple including a backspan and a first leg extending from the backspan. The first leg is divided into a first traversing leg portion and a first linear clenching leg portion by a first bend. A second leg also extends from the backspan and is divided into a second traversing leg portion and a second linear clenching leg portion by a second bend. At least one of the first and second linear clenching leg portions is oriented parallel to the backspan. In one embodiment, both the first and second linear clenching leg portions are oriented parallel to the backspan.
At least one of the first and second traversing leg portions is oriented perpendicular to the backspan. In a specific embodiment, both the first and second traversing leg portions are oriented perpendicular to the backspan.
In one embodiment, a combined length of the first and second clenching leg portions is less than an overall length of the backspan. In an alternative embodiment, the combined length of the first and second clenching leg portions is equal to an overall length of the backspan. In a specific embodiment, the combined length of the first and second clenching leg portions is greater than an overall length of the backspan.
There is also disclosed a box staple assembly for use in tissue which generally includes a backspan and first and second legs extending from the backspan. The first leg is divided into a first traversing leg portion and a first linear clenching leg portion by a first bend. The second leg is also divided into a second traversing leg portion and a second linear clenching leg portion by a second bend. A staple plate is positioned on the first and second legs between the backspan and the first and second linear clenching leg portions. At least one of the first and second linear clenching leg portions is oriented parallel to the staple plate.
The staple plate has first and second holes to receive the first and second traversing leg portions respectively. An overall length of the staple plate is greater than an overall length of the backspan and the distance between the first and second holes is substantially equal to the overall length of the backspan.
There is also disclosed a method of forming a box staple through tissue including the step of providing a box staple of having a backspan, a first leg extending from the backspan and including a first bend zone located between the backspan and a first end of the first leg, and a second the leg extending from the backspan and including a second bend zone located between the backspan and a second end of the second leg. The first and second ends of the first and second legs are driven through a tissue section. The first leg is impacted in the first bend zone with a first angled portion of a first anvil to form a first bend within the first bend zone and dividing in the first bend zone into a first traversing leg portion and a first linear clenching leg portion.
The method further includes the step of impacting the first linear clenching leg portion with a first finishing surface of the first anvil to orient the first linear clenching leg portion parallel to the backspan.
The method further includes the step of impacting the second leg in the second bend zone with a second angled portion of a second anvil to form a second bend within the second bend zone and dividing the second bend zone into a second traversing leg portion and a second linear clenching leg portion.
The second linear clenching leg portion is impacted with a second finishing surface of the second anvil to orient the second linear clenching leg portion parallel to the backspan.
In one embodiment of the disclosed method, the first and second ends are driven through tissue such that the backspan engages an upper surface of the tissue.
In a further embodiment of the disclosed method, a staple plate is positioned over the first and second legs and engages an underside of the tissue prior to the step of impacting the first leg in the first bend zone.
In a particular embodiment, the first linear clenching leg portion is oriented parallel to the staple plate.
DESCRIPTION OF THE DRAWINGS
Embodiments of the presently disclosed box staple and box staple assembly are disclosed herein with reference to the drawings, wherein:
FIG. 1 is a side view, partially shown in section, of one embodiment of a disclosed box staple formed through a pair of tissue sections;
FIG. 2 is an end view taken along line 2 - 2 of FIG. 1 ;
FIG. 3 is a top view taken along line 3 - 3 of FIG. 1 ;
FIG. 4 is a bottom view taken along line 4 - 4 of FIG. 1 ;
FIG. 5 is a side view, partially shown in section, of the box staple of FIG. 1 , inserted through the pair of relatively thick tissue sections, immediately prior to formation;
FIG. 6 is a side view similar to FIG. 5 during formation of the box staple through the pair of relatively thick tissue sections;
FIG. 7 is a side view similar to FIG. 6 after formation of the box staple through the pair of relatively thick tissue sections;
FIG. 8 is perspective view of the fully formed box staple;
FIG. 9 is a side view, partially shown in section, of the box staple formed through a pair of relatively thin tissue sections;
FIG. 10 is a top view taken along line 10 - 10 of FIG. 9 ;
FIG. 11 is an end view taken along line 11 - 11 of FIG. 9 ;
FIG. 12 is a bottom view taken along line 12 - 12 of FIG. 9 ;
FIG. 13 is a side view, partially shown in section, of the box staple immediately prior to formation through the pair of relatively thin tissue sections;
FIG. 14 is a side view similar to FIG. 13 during formation of the box staple through the pair of relatively thin tissue sections;
FIG. 15 is similar to FIG. 14 after formation of the box staple through the pair of relatively thin tissue sections;
FIG. 16 is a perspective view of a box staple assembly including a box staple and a staple plate;
FIG. 17 is a side view, partially shown in section, of the box staple assembly formed through a pair of relatively thick tissue sections;
FIG. 18 is an end view taken along line 18 - 18 of FIG. 17 ;
FIG. 19 is a top view taken along line 19 - 19 of FIG. 17 ;
FIG. 20 is a bottom view taken along line 20 - 20 of FIG. 17 ;
FIG. 21 is a side view, partially shown in section, of the box staple assembly immediately prior to formation through the pair of relatively thick tissue sections;
FIG. 22 is a side view, similar to FIG. 21 , during formation of the box staple assembly through the pair of relatively thick tissue sections;
FIG. 23 is a side view, similar to FIG. 22 , after formation of the box staple assembly through the pair of relatively thick tissue sections;
FIG. 24 is side view, partially shown in section, of the box staple assembly formed through a pair of relatively thin tissue sections;
FIG. 25 is a top view taken along line 25 - 25 of FIG. 24 ;
FIG. 26 is a bottom view taken along line 26 - 26 of FIG. 24 ;
FIG. 27 is an end view taken along line 27 - 27 of FIG. 24 ;
FIG. 28 is a side view, partially shown in section, of an alternate embodiment of a staple assembly including a staple and an arcuate staple plate formed through a pair of relatively thick tissue sections; and
FIG. 29 is a side view, partially shown in section, of the staple assembly of FIG. 28 formed through a pair of relatively thin tissue sections.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiments of the presently disclosed box staple and box staple assembly will now be described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, i.e. surgeon or physician, while the term “distal” refers to that part or component further away from the user.
Referring to FIG. 1-4 , and initially to FIG. 1 , there is disclosed an embodiment of a universal or box staple 10 for use in various thickness of tissues. Box staple 10 has the further advantage of providing uniform pressure against the underside of the tissues stapled as described in more detail hereinbelow. Box staple 10 generally includes a backspan 12 and first and second legs 14 and 16 , respectively, extending distally from backspan 12 . Specifically, a proximal end 18 of first leg 14 extends distally from a first end 20 of backspan 12 and a proximal end 22 of second leg 16 extends distally from a second end 24 of backspan 12 . First leg 14 terminates in a tissue penetrating distal tip 26 and second leg 16 terminates in a tissue penetrating distal tip 28 .
Box staple 10 is formed from a length of material having a generally rectangular cross-section. Box staple 10 can be formed from any number of biocompatible materials such as, for example, stainless steel, titanium, various malleable plastic materials, various bio-absorbable materials etc. When formed from metallic materials such as stainless steel or titanium, box staple 10 can be formed by drawing and cutting a length of metallic wire, stamping box staple 10 from a sheet of metallic material, etc. Likewise, when box staple 10 is formed from a plastic or bio-absorbable material, box staple 10 can be formed by injection molding, carving box staple 10 from a block of plastic material, etc.
As noted above, box staple 10 is designed for use in tissues of various thicknesses, such as, for example, relatively thick tissues A and B. In order to accommodate the various thickness tissues without excessive or insufficient compression of tissues A and B, first leg 14 has a first bend zone 30 which extends substantially between proximal end 18 and tissue penetrating distal tip 26 of first leg 14 . Depending upon the thickness of the tissues encountered, first leg 14 can be bent at any location within bend zone 30 to accommodate those tissues. This is facilitated by the use of a pair of driven anvils as described in more detail herein below. Second leg 16 also includes a second bend zone 32 which extends substantially between proximal end 22 and tissue penetrating distal tip 28 of second leg 16 .
When box staple 10 is fully formed through relatively thick tissues A and B, backspan 12 provides uniform compression on an upper surface C of relatively thick tissue section A ( FIGS. 1 and 3 ). First leg 14 is formed with a first bend 34 in first transition zone 30 such that first leg 14 is divided into a first, substantially linear traversing leg portion 36 extending through relatively thick tissues A and B ( FIG. 1 ) and a first substantially linear clenching leg portion 38 lying flush with an underside D of relatively thick tissue section B ( FIGS. 1 and 4 ). It should be noted that, first bend 34 formed between first traversing leg portion 36 and first clenching leg portion 38 is a substantially sharp or abrupt 90° bend in contrast to the relatively gradually curving bends typically associated with prior art staples. Likewise, second leg 16 is formed with a second bend 40 in second bend zone 32 which divides second leg 16 into a second substantially linear traversing leg portion 42 extending through relatively thick tissue sections A and B ( FIGS. 1 and 2 ) and a second substantially linear clenching leg portion 44 lying flush with underside D of relatively thick tissue section B. ( FIGS. 1 and 4 ). Second bend 40 also forms a relatively sharp or abrupt 90° transition between second traversing leg portion 42 and second clenching like portion 44 . By maintaining first and second clenching leg portions 38 and 44 in a relatively linear or straight configuration against underside D of relatively thick tissue section B, first clenching leg portion 38 and second clenching leg portion 44 maintain a uniform compression against underside D without the associated pinching or tip penetration of underside D as is common with the use of conventional staples whose leg distal ends are typically formed into a recurved shape penetrating back into the tissue.
As best shown in FIG. 1 , when box staple 10 is formed through of relatively thick tissue sections A and B, the length L 1 of backspan 12 is greater than or equal to the combined lengths L 2 and L 3 of first and second linear clenching leg portions 38 and 44 , respectively.
Referring now to FIGS. 5-7 , and initially with respect to FIG. 5 , the use and formation of box staple 10 with relatively thick tissue sections A and B will now be described. Initially, the dimensions of box staple 10 are chosen such that legs 14 and 16 have overall lengths L 4 and L 5 which are substantially greater than the anticipated combine thicknesses of any tissues to be encountered. Furthermore, each of the overall lengths L 4 and L 5 of first and second legs 14 and 16 , respectively, is greater than half the overall length L 1 of backspan 12 . This ensures sufficient leg length to traverse and secure both relatively thick and thin tissue sections. Box staple 10 is initially driven through relatively thick tissue sections A and B by engaging backspan 12 with a staple driver (not shown) thereby driving first and second tissue penetrating distal tips 26 and 28 , respectively, through tissue sections A and B.
Referring to FIG. 6 , thereafter, a pair of anvils, such as, for example, first and second driven anvils 50 and 52 , are driven laterally against first and second staple legs 14 and 16 to form box staple 10 through relatively thick tissue sections A and B. First and second driven anvils 50 and 52 generally include respective first and second angled surfaces 54 and 56 and respective first and second finishing surfaces 58 and 60 . First and second angled surfaces 54 and 56 are provided to initially impact or impinge against first and second legs 14 and 16 within the respective first and second bend zones 30 and 32 to initially create first and second bends 34 and 40 . This divides first bend zone 30 of first leg 14 into first traversing leg portion 36 and first linear clenching leg portion 38 . Similarly, this divides second bend zone 32 into second traversing leg portion 42 and second linear clenching leg portion 44 .
Referring to FIG. 7 , as first and second anvils 50 and 52 are driven to the final position, first and second linear clenching leg portions 38 and 44 engaged by relatively linear finishing surfaces 58 and 60 of driven anvils 50 and 52 , respectively such that first and second linear clenching leg portions 38 and 44 are brought flush into engagement with underside D of relatively thick tissue section B. As noted here in above, when box staple 10 is used in relatively thin tissue sections, the combined lengths L 2 and L 3 of first and second clenching leg portions 38 and 44 , respectively, are substantially less than or equal to the overall length L 1 of backspan 12 .
Referring now to FIGS. 8-12 , and initially with regard to FIG. 8 , box staple 10 is illustrated in the configuration it assumes when used through a pair of relatively thin tissue sections. Specifically, when box staple 10 is formed through relatively thin tissue sections, each of the lengths L 2 and L 3 of respective first and second linear clenching leg portions 38 and 44 are greater than the overall length L 1 of backspan 12 .
As shown in FIG. 9 , first and second traversing leg portions 36 and 42 pass through thin tissue sections E and F. First and second the linear clenching leg portions 38 and 44 lie parallel to tissue section F. As best shown in FIG. 10 , backspan 12 engages an upper surface G of tissue section E while first and second linear clenching leg portions 38 and 44 engaged an underside surface H of tissue G.
As best shown in FIGS. 8 , 11 and 12 , the excess lengths of first and second clenching leg portions 38 and 44 are accommodated by allowing them to lie in parallel relation to each other against underside F of tissue H. Thus, box staple 10 functions as a universal staple suitable for use with both thick and thin tissue sections without risk of penetrating the tissue sections with first and second tissue penetrating distal tips 26 and 28 of respective first and second legs 14 and 16 .
Referring now to FIGS. 13-15 , in order to form box staple 10 through pair of relatively thin tissue sections E and F, box staple 10 is initially driven through tissue sections E and F. Thereafter, driven anvils 50 and 52 impact staple legs 14 and 16 to initially begin to bend staple legs 14 and 16 . As shown in FIG. 14 , angled faces 54 and 56 of driven staples 50 and 52 initially form bends 34 and 40 to create respective first and second traversing leg portions 36 and 42 and first and second linear clenching leg portions 38 and 44 . Thereafter, with reference to FIG. 15 , finishing surfaces 58 and 60 of driven anvils 50 and 52 engage first and second linear clenching leg portions 38 and 44 to form first and second linear clenching leg portions 38 and 44 against underside H of tissue F and, more importantly, parallel to backspan 12 . Thus, box staple 10 is particularly suited to use with relatively thin tissue sections such that first and second linear clenching leg portions 38 and 44 a lie flush against the tissue to be stapled.
Referring now to FIGS. 16-20 , and initially with regard to FIG. 16 there is disclosed a box staple assembly 70 including box staple 10 and a pledget or staple plate 72 . Staple plate 72 increases the surface area engaging a tissue being stapled as well as protecting the tissue from engagement with staple legs 14 and 16 upon crimping of box staple 10 about tissue. Box staple 10 is as described herein above including backspan 12 and legs 14 and 16 extending from backspan 12 .
Staple plate 72 is substantially rectangular having first and second holes 74 and 76 adjacent first and second ends 78 and 80 , respectively, of staple plate 72 . First and second holes 74 and 76 are configured to receive first and second legs 14 and 16 , of box staple 10 , therethrough. Staple plate 72 has an overall length L 4 which is greater than the length L 1 of backspan 12 ( FIG. 1 ). Additionally, the spacing or length L 5 between holes 74 and 76 is substantially identical to the length L 1 of backspan 12 .
As best shown in FIGS. 17 and 18 , box staple assembly 70 is provided to secure a pair of tissue sections, such as, for example, tissue sections I and J. Backspan 12 engages an upper surface K of tissue section I ( FIG. 19 ) while an upper surface 82 of staple plate 72 engages a lower surface L of tissue section J ( FIG. 20 ).
Referring to FIG. 20 , as noted herein above, staple plate 72 protects tissue section J from engagement with first and second clenching leg portions 38 and 44 of first and second legs 14 and 16 , respectively. Specifically, upon formation of staple 10 through tissue sections I and J, staple plate 72 is interposed between tissue section J and first and second clenching leg portions 38 and 44 .
Referring to FIGS. 21-23 , the use of box staple assembly 70 to secure a pair of relatively thick tissue sections I and J together will now be described. With reference to FIG. 21 , initially, box staple 10 is driven by a staple driver (not shown) toward tissue sections I and J such that first and second legs 14 and 16 penetrate tissue sections I and J until backspan 12 engages upper surface K of tissue section I. Staple plate 72 is positioned against undersurface K of tissue section J and legs 14 and 16 are extended through holes 74 and 76 a staple plate 72 . This brings upper surface 82 of staple plate 72 into engagement with undersurface K of tissue section J.
With reference to FIGS. 21 and 22 , thereafter, first and second driven anvils 50 and 52 are moved inwardly toward first and second legs 14 and 16 . Upon engagement of first and second angled surfaces 54 and 56 with first and second legs 14 and 16 , first and second legs 14 and 16 are initially bent within respective bend zones 30 and 32 to form first and second bends 34 and 40 within first and second legs 14 and 16 . As noted here in above, first bend 34 divides first leg 14 into first traversing leg portion 36 and first linear clenching leg portion 36 while second bend 40 divides second legs 16 into second traversing leg portion 42 and second linear clenching leg portion 44 . Notably, the extension of first and second legs 14 and 16 through first and second holes 74 and 76 in staple plate 72 facilitate forming bends 74 and 76 at substantially right angles relative to first and second traversing leg portions 36 and 38 of first and second legs 14 and 16 , respectively.
Finally, with reference to FIG. 23 , engagement of first and second finishing surfaces 58 and 60 of the first and second driven anvils 50 and 52 with first and second linear clenching leg portions 38 and 44 serve to secure first and second linear clenching leg portions 38 and 44 against underside 84 of staple plate 72 thereby securing staple plate 84 against underside L of tissue section J.
Referring now to FIGS. 24-27 , the use of box staple assembly 70 to secure a pair of relatively thin tissue sections, such as, for example, tissue sections M and N will now be described. The method disclosed herein with respect to relatively thin tissue sections M and N is substantially identical to the method disclosed herein above with respect to relatively thick tissue sections I and J. Initially, with reference to FIG. 24 , staple 10 is driven by a staple driver (not shown) such that first and second legs 14 and 16 are driven through tissue sections M and N until backspan 12 engages an upper surface O of tissue section M ( FIG. 25 ). First and second legs 14 and 16 are then inserted through holes 74 and 76 of staple plate 72 . Thereafter, first and second driven anvils 50 and 52 ( FIGS. 21-23 ) are moved to form first and second linear clenching leg portions 38 and 44 against underside 84 of staple plate 72 ( FIG. 26 ).
As best shown in FIGS. 26 and 27 , similar to that disclosed herein above with respect to box staple 10 in FIGS. 11 and 12 , first and second linear clenching leg portions 38 and 44 are in a side-by-side and overlapping relation with respect to each other due to the excess lengths of legs 14 and 16 wine used through relatively thin tissue sections M and N. In this manner, the provision of box staple 10 having first and second legs 14 and 16 with overall lengths greater then at least the overall length of backspan 12 allows box staple 10 to function as a universal staple suitable for use with various thicknesses of tissue. As noted herein above, the provision of staple plate 72 provides additional surface bearing area against the tissue section while facilitating forming an abrupt 90° bend within first and second legs 14 and 16 .
Referring now to FIGS. 28 and 29 , while staple plate 72 has been disclosed for use with box staple 10 , staple plate 72 may be formed of a material which allows staple plate 72 to be used with a staple and 90 similar to box staple 10 in situations wherein staple 90 is formed with conventional anvils. As used herein, the term “conventional anvils” refers to those anvils having arcuate anvil pockets resulting in arcuate rather than linear clenching leg portions in the formed staple.
For example, with reference to FIG. 28 , staple 90 includes a backspan 92 having first and second legs 94 and 96 extending from backspan 92 . In use, staple 90 is driven through relatively thick tissue sections Q and R resulting in first and second traversing leg portions 98 and 100 extending through tissue sections Q and R while backspan 92 engages an upper surface S of tissue section Q. First and second legs 94 and 96 are extended through holes 74 and 76 in staple plate 72 and are clenched against staple plate 72 by arcuate anvil pockets formed in an anvil associated with a conventional stapler (not shown).
Similarly, with reference to FIG. 29 , when used in conjunction with relatively thin tissue sections U and V, backspan 92 engages an upper surface W of tissue section U while traversing leg portions 98 and 100 extending through tissue sections U and V. Staple plate 72 bears against an undersurface X of tissue section V. First and second linear clenching leg portions 102 and 104 of first and second legs 94 and 96 are formed into a roughly arcuate overlapping relation due to the excess length of legs 94 and 96 .
It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the legs of the disclosed box staple maybe heat treated at specific points to facilitate the formation of the abrupt 90° bend between the traversing portion of the leg and the linear clenching portion of the leg. Further, alternative embodiments of anvils may be provided to form the substantially right angle within their respective legs. Additionally, the disclosed box staple may be formed from any shape memory alloy such that the right angle between the traversing leg portion and the linear clenching leg portion is formed at a predetermined location along the length of the leg. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | A staple is provided having a backspan and a first and second legs extending distally from the backspan. Each of the first and second legs includes a bend dividing each leg into a traversing leg portion and a substantially linear clenching leg portion. A staple plate is positionable over the first and second legs between the backspan and the first and second clenching leg portions. An anvil assembly has first and second movable members which move toward to one another to engage outer surfaces of the first and second clenching leg portions. There is further disclosed a method of forming the staple through tissue. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to multifunctional lubricant additives for imparting antiwear and extreme pressure properties. In particular, the invention relates to novel hydroxyalkyldithiocarbamate borate esters and the process for preparing such compounds, as well as the precursor compounds and lubricating compositions containing such compounds.
[0003] 2. Description of the Prior Art
[0004] The development of lubricants represents an important area of technology aimed at finding ways to reduce friction between contacted moving components in various mechanical devices. The mechanical wear of these components is greatly accelerated by friction, thus increasing the expense of operating mechanical devices.
[0005] A variety of additives are used in lubricants to substantially improve performance. For example, extreme pressure (EP) additives are routinely incorporated into an untreated lubricating composition (e.g., greases) to significantly improve performance. Extreme pressure additives are believed to produce a film on the surface of the metal which can both increase the load carrying capacity of the lubricant, and protects the metal surface under high load conditions from deterioration due to wear, welding, and abrasion.
[0006] Lead naphthenates and lead dialkyldithiocarbamates are frequently used as additives to improve the EP performance of greases. However, lead is a heavy metal which is considered “poisonous” in all forms. As an alternative, metal additives (such as antimony, zinc, and bismuth) have been used as a replacement for lead. However, these heavy metals still provide environmental concerns regarding the use. Accordingly, it has long been a goal in the art to develop non-metal lubricating materials to replace heavy metal additives while providing acceptable extreme pressure performance.
[0007] Ashless dithiocarbamates, such as 4,4′-methylene bis(dibutyl dithiocarbamate) (Trade mark VANLUBE® 7723 available from R.T. Vanderbilt Company, Inc.), are also well known for their antioxidant and extreme pressure properties in lubricants.
[0008] Borates and borate esters are well-known to exhibit antiwear and other properties in lubricant applications. U.S. Pat. No. 905,649 from Chapman describes the use of borax in a grease composition. U.S. Pat. No. 2,234,581 from Rosen describes lubricating oils and greases containing a boron-containing compound useful in lubricants. U.S. Pat. No. 3,185,644 from Knowles, et al., describes amine salts of borate esters that are useful as lubricant additives. U.S. Pat. Nos. 3,224,971 and 3,239,643, also attributed to Knowles, et al., describes novel borate esters and lubricant compositions thereof. More recently, U.S. Pat. No. 5,698,499 from Baranski, et. al., describes phenolic borates that are useful antiwear additives.
[0009] More recently, there have been reported multifunctional additives that combine both the antiwear capabilities of borates and borate esters with the extreme pressure and antioxidant properties found in ashless sulfur-containing compounds. U.S. Pat. Nos. 3,303,130, 5,885,943 and 6,028,210 describe the preparation of borate thioesters useful as antiwear additives and antioxidants. U.S. Pat. Nos. 5,126,063, 5,182,036, 5,370,806, and 5,698,498 describe the preparation of borated dithiocarbamate esters that are useful as antiwear, extreme pressure and antioxidant additives. These materials are prepared from dithiocarbamate salts and their reaction with and epoxide compound, followed by reaction with boric acid to form the borated dithiocarbamate ester. A borated dithiocarbamate is described by Chiu in U.S. Pat. No. 5,672,727.
SUMMARY OF THE INVENTION
[0010] The present invention describes the preparation of novel hydroxyalkyldithiocarbamate borate ester compounds and their novel precursors that are useful as antiwear and extreme pressure additives. This is accomplished by the reaction of a hydroxyalkylamine compound with carbon disulfide and an acrylate or maleate compound, followed by the reaction with boric acid.
[0011] The invention also relates to novel hydroxyalkyldithiocarbamate borate ester compounds formed from the reaction products of the novel hydroxyalkyldithiocarbamate ester compounds with boric acid and alcohols or glycols to form novel hydroxyalkyldithiocarbamate borate esters which provide from 0.5 to 5% B and 0.5 to 30% S by weight.
[0012] Another object of this invention concerns lubricating compositions comprising a major portion of a lubricating oil or grease and the hydroxyalkyldithiocarbamate borate ester compounds prepared herein.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Hydroxyalkyldithiocarbamate Esters
[0013] Some of the hydroxyalkyldithiocarbamate esters used in this invention are the reaction products of hydroxylalkylamines and carbon disulfide with acrylates or maleates as described in Scheme I. The hydroxyalkylamine and acrylate or maleate is added to a reaction flask and carbon disulfide is then added slowly. The reaction is then heated carefully to a temperature between 60 and 120° C. for a period between 1 and 8 hours. Occasionally a solvent such as isopropanol is used. After the period of reaction, the excess carbon disulfide and solvent is stripped, yielding the product.
[0014] Examples of hydroxyalkylamines that can be used in this invention include ethanolamine, diethanolamine, 2-(methylamino)ethanol, 2-(ethylamino)ethanol, 2-(propylamino)ethanol, 2-(butylamino)ethanol, 2-(tertbutylamino)ethanol, 2-(isopropylamino)ethanol, 2-(propylamino)ethanol, diisopropanolamine, 2-(diisopropylamino)ethanol, 3-Methylamino-1,2-propanediol, and 3-[(2-hydroxyethyl)amino]-1-propanol. The preferred hydroxyalkylamines are diethanolamine, 2-(methylamino)ethanol, 2-(ethylamino)ethanol, 2-(propylamino)ethanol, 2-(butylamino)ethanol, and diisopropanolamine.
[0015] Examples of acrylates that can be used in this invention include methyl acrylate, vinyl acrylate, methyl methacrylate, ethyl acrylate, ethyl crotonate, allyl methacrylate, tert-butyl acrylate, isobutyl acrylate, methyl-2-hexenoate, butyl acrylate, isobutyl acrylate, ethyl sorbate, isopentyl acrylate, tert-butyl methacrylate, butyl methacrylate, isobutyl methacrylate, methyl-2-octenoate, hexyl acrylate, methyl-2-nonenoate, ethyl-2-octenoate, hexyl-2-butenoate, methyl-2-decenoate, isooctyl acrylate, 2-ethylhexyl acrylate, ethyl-2-methyl-2-nonenoate, 2-ethylhexyl 2-methylacrylate, decyl acrylate, decyl 2-methylacrylate, 8-methylnonyl 2-methylacrylate, and dodecyl acrylate. The preferred acrylates in this invention are methyl acrylate, butyl acrylate, and dodecyl acrylate. Examples of maleates that can be used in this invention include dimethyl maleate, diethyl maleate, dipropyl maleate, dibutyl maleate, dihexyl maleate, dioctyl maleate, and bis(2-ethylhexyl)maleate. The preferred maleates are dibutyl maleate and bis(2-ethylhexyl)ethylhexyl)maleate.
[0000] Borate Esters
[0016] The borate esters used in this invention are the reaction products of the hydroxylalkyldithiocarbamate esters described above with boric acid at a temperature between 80 and 150° C., as shown in Scheme II. Alcohols can also be added to the reaction to produce a mixed product that contains both alkoxy and hydroxyalkyldithiocarbamate ester on the boron. (Scheme III) The hydroxyalkyldithiocarbamate ester and boric acid are added to a reaction flask, and then the mixture is heated to a temperature between 80 and 150° C. The mixture is heated until the expected amount of water is liberated from the reaction, usually three equivalents per boron. The material is then filtered, revealing the product.
Examples of alcohols that can be used in this invention include methanol, ethanol, propanol, isopropanol, butanol, isobutanol, tertbutanol, basically all chain lengths can be used. Fatty alcohol mixtures such as those marketed under the trade name Alfol® by Sasol North America, and those marketed by The Procter and Gamble Company can also be used. These mixtures range from C 8 to C 18 in alkyl chain length. The preferred alcohols used are the long-chain fatty alcohol mixtures, 2-ethylhexanol, and butanol.
Lubricant Compositions
[0017] The borate ester compositions provide excellent antiwear and extreme pressure properties when incorporated into a lubricating formulation. The borate ester compositions of the invention may be present in a lubricating formulation at from about 0.01-10 mass %, preferably about 0.1-5 mass %, and more preferably about 1-3 mass %.
[0018] For ease of incorporation into the lubricating formulation, the reaction product can be dissolved in or diluted with a diluent compatible with the lubricating formulation. The base oil of the lubricants may be selected from naphthenic, aromatic, paraffinic, mineral and synthetic oils. The synthetic oils may be selected from, among others, alkylene polymers, polysiloxanes, carboxylic acid esters and polyglycol ethers.
[0019] The lubricating compositions may contain the necessary ingredients to formulate the composition, as for example emulsifiers, dispersants and viscosity improvers. Greases may be prepared by adding thickeners, as for example, salts and complexes of fatty acids, polyurea compounds, clays and quaternary ammonium bentonite complexes.
[0020] Depending on the intended use of the lubricant, other functional additives may be added to enhance a particular property of the lubricant. The lubricating compositions may further contain extreme pressure agents, metal passivators, rust inhibitors, dispersants and other known antioxidants, antifriction, and antiwear agents. Examples of extreme pressure agents include sulfurized olefins, 2,5-dimercaptothiadiazole derivatives, metal dithiocarbamate complexes, metal dithiophosphate complexes, and organic dithiocarbamate esters. Examples of common antioxidants include alkylated diphenyl amines, hindered phenols, polyphenyl thioethers, alkylated napthylamines, alkylated dinapthylamines, zinc dithiophosphates, and zinc dithiocarbamates. Examples of antifriction additives include molybdenum dithiocarbamates, molybdate esters, molybdenum amine complexes, and molybdenum dithiophosphates.
[0021] Examples of friction modifiers include fatty amines, mono- and diethoxylated amines, carboxylic acids, amides, imides, alcohols, phenols, esters, thiols, sulfonic acids, phosphates, phosphates.
EXAMPLES
Example 1
[0022] To diethanolamine (36.95 g, 0.35 moles) and dibutylmaleate (81.03 g, 0.35 moles) was added CS 2 (28.04 g, 0.37 moles) dropwise over a 15 minute period. The mixture was then heated to 80° C. for 6 hours followed by removal of the excess CS 2 to give 141.04 g (96.5% yield) of a yellow liquid.
Example 2
[0023] To dibutylmaleate (136.97 g, 0.60 moles) and 2-(ethylamino)ethanol (53.48 g, 0.60 moles) was added CS 2 (60.00 g, 0.79 moles) over a 10 minute period. The mixture was then heated at 70° C. for 6.5 hours to give 222.46 g (94% yield) of a thick yellow liquid after the excess CS 2 was distilled off.
Example 3
[0024] To the product of Example 2 (68.1 g, 0.173 moles) was added 2-ethylhexanol, (45.07 g, 0.346 moles) boric acid, (10.70 g, 0.173 moles) and 80 g of toluene. The mixture was then heated at 100-125° C. for 6 hours. 9.3 g of water was distilled off as well as the toluene, which gave 110.52 g of product following filtration and analyzing as having 1.7% B and 7.5% S by weight.
Example 4
[0025] To the product of Example 2 (78.53 g, 0.20 moles) was added boric acid, (4.00 g, 0.061 moles) and 80 g of toluene. The mixture was then heated at 100-125° C. for 6 hours. 3.6 g of water was distilled off as well as the toluene, which gave 80.53 g of product following filtration.
Example 5
[0026] To 2-ethylhexyl acrylate (67.10 g, 0.36 moles) and 2-(ethylamino)ethanol (32.46 g, 0.36 moles) was added CS 2 (32.00 g, 0.42 moles) over a 10 minute period. The mixture was then heated at 70° C. for 7 hours to give 113.43 g (90% yield) of a thick yellow liquid after the excess CS 2 was distilled off.
Example 6
[0027] To the reaction product of example 5 (57.51 g, 0.17 moles) was added Exxal® 13 (68.15 g), boric acid, (10.21 g, 0.17 moles) and 60 g of toluene. The mixture was then heated at 110° C. for 4 hours. 3.6 g of water was distilled off as well as the toluene, which gave 80.53 g of product following filtration.
Example 7
[0028] To 2-ethylaminoethanol (24.00 g, 0.27 moles) and Di-2-ethylhexyl maleate (95.19 g, 0.27 moles) was added carbon disulfide (50 g, 0.65 moles) dropwise with stirring. The mixture was then heated at 50° C. for 2 hours, then 70° C. for 3 hours. The reaction was then cooled to give 135.84 g of product following distillation of the excess carbon disulfide.
Example 8
[0029] To the reaction product of Example 7 (77.49 g, 0.15 moles) was added Exxal® 13 (72.00 g), boric acid, (9.00 g, 0.15 moles) and 50 g of toluene. The mixture was then heated at 110° C. for 6 hours. 7.86 g of water was distilled off as well as the toluene, which gave 134.5 g of product following filtration and analyzing as 1.0% B and 6.2% S by weight.
Example 9
[0030] To 2-(butylamino)ethanol (53.50 g, 0.46 moles) and Di-2-ethylhexyl maleate (155.45 g, 0.46 moles) was added carbon disulfide (36.00 g, 0.47 moles) dropwise with stirring. The mixture was then heated at 50° C. for 2 hours, then 70° C. for 2 hours. The reaction was then cooled to give 240.80 g of product following distillation of the excess carbon disulfide.
Example 10
[0031] To the reaction product of Example 9 (67.25 g, 0.13 moles) was added boric acid, (2.47 g, 0.04 moles) and 150 g of toluene. The mixture was then heated at 110° C. for 6 hours. 2.11 g of water was distilled off as well as the toluene, which gave 72.71 g of product following filtration and analyzing as having 1.0% B by weight.
Example 11
[0032] To diethanolamine (35.51 g, 0.34 moles), di-2-ethylhexyl maleate (115.00 g, 0.46 moles), and 70 g of isopropanol was added carbon disulfide (40.00 g, 0.53 moles) dropwise with stirring. The mixture was then heated at 50° C. for 2 hours, then 75-80° C. for 2 hours. The reaction was then cooled to give 174.17 g of product following distillation of the excess carbon disulfide and isopropanol.
Example 12
[0033] To diethanolamine (34.14 g, 0.32 moles), lauryl acrylate (90%) (86.73 g, 0.32 moles), and 70 g of isopropanol was added carbon disulfide (40.00 g, 0.53 moles) dropwise with stirring. The mixture was then heated at 50° C. for 2 hours, then 75-80° C. for 2 hours. The reaction was then cooled to give 136.51 g of product following distillation of the excess carbon disulfide and isopropanol.
Example 13
[0034] To the reaction product of Example 12 (51.06 g, 0. moles) was added boric acid, (3.20 g, 0.04 moles). The mixture was then heated at 110° C. for 6 hours under aspirator vacuum. 2.80 g of water was distilled off, and 72.71 g of product was recovered following filtration and analyzing as having 1.0% B and 12.1% S by weight.
Example 14
[0035] To 2-(butylamino)ethanol (29.10 g, 0.25 moles), lauryl acrylate (90%) (66.06 g, 0.25 moles), and 70 g of isopropanol was added carbon disulfide (21.00 g, 0.28 moles) dropwise with stirring. The mixture was then heated at 50° C. for 2 hours, then 75-80° C. for 2 hours. The reaction was then cooled to give 11.02 g of product following distillation of the excess carbon disulfide and isopropanol.
Example 15
[0036] To the reaction product of Example 16 (32.04 g, 0.07 moles) was added boric acid (4.20 g, 0.071 moles) and 75 g of toluene. The mixture was then heated at 110° C. for 6 hours under aspirator vacuum. 1.1 mL of water was distilled off as well as the toluene, which gave 33.14 g of product following filtration.
Example 16
[0000] Falex Pin and Vee Block Tests
[0037] A laboratory test was conducted by using the original Falex machine to simulate the valve train wear of an automobile engine. The V-blocks and pin were washed in mineral spirits with an ultrasonic cleaner, rinsed with acetone, air dried and weighed. The test sample (60 g) was placed into the oil cup. The motor was switched on and the loading arm was placed on the ratchet wheel. Upon reaching the reference load of 227 Kg, the ratchet wheel was disengaged and the load was maintained constant for 1 or 3.5 hours. Thereafter, the motor was switched off. The V-blocks and pin were washed, dried and weighed. The weight loss, a measure of wear, was recorded and compiled in Table I.
[0038] The test samples were prepared by adding the borate ester compound to a base oil, Uninap® SD 100 (manufactured by Unisource Energy, Inc.). Boron content was determined by Atomic Absorption techniques prior to dilution. The results are listed in Table 1.
TABLE 1 Mass Percent Example 3 Product 1 Example 8 Product 1 1.63 Example 10 Product 2 Example 13 Product 1 Lubrizol Z 1395 * 1.5 2.0 5 Uninap 100 SD 99 99 98.37 98 99 98.5 98.0 95 ppm B ˜170 ˜100 ˜163 ˜100 ˜100 0 0 0 % P 0 0 0 0 0 0.14 0.19 0.47 Falex Pin & Vee Block 227 Kg for 60 minutes Total Mass Loss (mg) 12.7 7.9 50.8 44.8 221 396 Actual Test Time (min.) 60 60 60 13 sec. 15 sec. 47 Falex Pin & Vee Block 227 Kg for 210 minutes Total Mass Loss (mg) 3.1 Actual Test Time (min.) 210 Falex Pin & Vee Block 227 Kg for 180 minutes Total Mass Loss (mg) 30.9 Actual Test Time (min.) 180 * Lubrizol Z 1395 is a zinc dithiophosphate manufactured by Lubrizol Corporation.
Example 17
[0000] 4-Ball Weld and Wear Tests
[0039] The reaction products of Examples 12 and 15 were evaluated for their 4-Ball Weld and 4-Ball Wear properties in accordance with ASTM 2596 and ASTM 2266 respectively. An oil formulation with Exxon ISO 220 Blend (manufactured by Exxon-Mobil Corporation) was prepared with the reaction product of Example 12, and a grease formulation was prepared with Exxon-Mobil Lithium-12 hydroxystearate grease (manufactured by Exxon-Mobil Corporation). The results are listed in Table 2.
TABLE 2 Mass Percent Example 10 Product 3 Example 13 Product 3 Exxon ISO 220 Blend 97 100 EM Li—12OH Grease 97 100 ppm B ˜150 ˜300 0 0 4-Ball Weld Load, Kgf 250 315 160 126 4-Ball Wear: 1200 rpm, 75° C., 0.38 0.5 0.55/0.49 0.77 1 hour 40 Kgf, mm 1800 rpm, 54o C., 0.54 0.87 1 hour 20 Kgf, mm | A novel hydroxyalkyldithiocarbamate borate ester compound is presented according to the formula:
where R=alkyl C 1 to C 25 ; R′═H or CO 2 R; R″═(CH 2 ) m OH where m=1 to 8, or alkyl C 1 to C 25 ; n=1 to 8. The borate ester compound is prepared by reacting boric acid with a novel hydroxyalkyldithiocarbamate ester compound according to the formula, and optionally with an alcohol:
where R, R′, R″ and n are as above. The hydroxyalkyldithiocarbamate ester is prepared by reacting a hydroxyalkylamine with CS 2 , and an acrylate or maleate compound. A lubricating composition is based on a major amount of lubricating oil and a minor amount of the hydroxyalkyldithiocarbamate borate ester. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a §371 national stage entry of International Application No. PCT/EP2008/064787, filed Oct. 31, 2008, which claims priority to Belgian Patent Application No. 2007/0572, filed Nov. 29, 2007, both of which are hereby incorporated by reference.
BACKGROUND
The invention relates to a drag head of a trailing suction hopper dredger according to the preamble of claim 1 . The invention relates more particularly to a drag head which comprises a rotatable visor connected to a suction pipe for discharging soil via the suction opening of the visor.
Such a drag head is known, for instance from EP-A-0892116. Described herein is a drag head consisting of a visor connected to a suction pipe. The visor generally has an upper wall and two side walls and is open on the underside, thereby creating a suction opening for the discharge of soil. The whole is fixed to the trailing suction hopper dredger by means of a drag pipe. In order to enable dredging of ground under water, the drag head is lowered with drag pipe and suction pipe under water at the position of the rear side of the trailing suction hopper dredger until it contacts the bottom under the influence of its own weight. The drag head is dragged over the bottom for dredging by the movement of the trailing suction hopper dredger, wherein the soil is loosened and is suctioned away with water via the suction pipe. The trailing suction hopper dredger is provided for this purpose with a suction pump. The loosening of the ground is facilitated in the known drag head by providing the visor with a series of teeth, which are generally arranged transversely of the sailing direction on a so-called toothed beam and which penetrate partially into the ground during the dredging. Water under pressure is also injected into the ground in order to fluidize it. All these measures are intended to increase the dredging efficiency, which in this application is understood to mean the volume of soil dredged per unit of time.
If the known drag head is applied on harder grounds, such as for instance in sandstone, coral, rock or highly compacted mud, large hard chunks can result during dredging due to the action of the teeth, and these are suctioned up in their entirety and may block the suction pipe or even damage or put the suction pump out of operation. Many grounds for dredging are also strewn with armaments, such as bombs. In order to avoid such undesirable objects causing problems, the known drag head, and more particularly the visor thereof, is provided with a catching construction in the form of for instance a grid. Such a framework of rods running crosswise, between which passage openings are situated, prevents undesirable objects which are larger than the passage openings from entering the suction pipe. It has however been found that this has an adverse effect on the dredging efficiency. A decrease in the dredging efficiency is caused, among other factors, by a part of the suction opening of the visor becoming blocked by the undesirable objects, whereby increasingly less soil can be suctioned up. The drag head must then be brought to the surface and cleaned, which takes up valuable time.
SUMMARY OF THE INVENTION
The present invention has for its object to provide a drag head of a trailing suction hopper dredger which provides adequate protection against the suctioning up of undesirable objects without this adversely affecting the dredging efficiency.
The drag head according to the invention comprises for this purpose a visor provided with a catching construction for undesirable objects, which catching construction closes the suction opening except for passage openings, wherein at least a number of passage openings have a variable passage area. Surprisingly achieved by providing a number of passage openings with a variable passage area is that the suction opening becomes blocked less quickly, or even not at all. Objects which have come to lie in the catching construction are also released again easily.
The known grid is greatly deformed and/or damaged during use. This is caused by the undesirable objects being drawn against the grid with great force (by the great suction force of the suction pump of the trailing suction hopper dredger and the own weight of the drag head and drag pipe) and becoming firmly lodged therein. Not only is removal difficult, but larger holes may also be created in the grid and/or between grid and visor side walls due to the deformation of the grid, whereby undesirable objects are no longer stopped. It has been found that the catching construction according to the invention deforms less than the known grid.
A preferred embodiment of the drag head according to the invention is characterized in that at least a number of passage openings have a passage area which can be enlarged. It has been found that such a preferred embodiment not only further reduces the necessity for cleaning, but also achieves that undesirable objects, even in the unlikely event they do become jammed in the catching construction, can be removed relatively easily therefrom.
A further preferred embodiment of the drag head according to the invention has the feature that the catching construction comprises a framework of rods which run crosswise and between which the passage openings are situated, wherein at least some of the rods are connected movably to the visor. A first series of rods is here preferably connected fixedly to the visor and a second series of rods connected movably to the visor. The first series of rods connected fixedly to the visor provides the necessary strength and rigidity of the catching construction. The second series of (movable) rods ensures that at least a number of passage openings between the rods have a variable passage area. It is noted that the rods are not necessarily cylindrical but can have any random cross-section. A further advantage of the present embodiment is that possibly damaged detachable elements can be replaced much more quickly than fixed components due to the fact that they are not fixed.
It is also advantageous to characterize the drag head according to the invention in that the second series of rods is connected movably to the first series of rods by means of a coupling slidable between two end stops arranged on the first series of rods. A rod of the second series can hereby slide over a rod of the first series, but only over a limited distance. The distance is determined by the position of the end stops, which is moreover adjustable in this preferred variant. In this preferred variant the number of end stops, the mutual distance therebetween and the number of rods of the second series can all be readily adapted to the conditions. The catching construction can thus easily be made suitable for the purpose of stopping bombs or for stopping rocks. A catching construction for bombs typically has passage areas of 10×10 cm, where a catching construction for rocks for a larger drag head must typically have passage areas of 40×30 cm. A catching construction for rocks is obtained from a catching construction for bombs in simple manner by removing therefrom a number of rods of the first series. This is also reversible.
The same advantages as stated above can be gained by characterizing the drag head according to the invention in that the second series of rods is connected movably to the first series of rods by means of a coupling slidable between two sleeves arranged on the first series of rods. A rod of the second series can hereby slide over a rod of the first series, but only over a limited distance, wherein the distance is determined by the length of the sleeves.
The drag head according to the invention preferably comprises a visor which is provided with a series of teeth which are arranged transversely of the sailing direction and which penetrate partially into the ground during dredging. Such a series of teeth regularly causes problems in the known drag head because undesirable objects, such as large rocks, become lodged between the grid and the teeth. This is less the case with the drag head according to the invention.
It is further advantageous when the catching construction of the drag head according to the invention is provided with a series of teeth. Such a series of teeth is preferably arranged on the first series of rods because these rods form part of the bearing construction of the visor and can therefore transmit considerable forces. The teeth of the present preferred variant are preferably arranged offset on the catching construction. For a given cutting distance (the distance between furrows made in the ground) the mutual distance between the teeth is thus increased. This reduces the chance of undesirable objects becoming lodged between the teeth.
In a further preferred embodiment of the drag head according to the invention the visor is provided with wear strips at the position of the underside of the side walls. Depending on the ground conditions these wear strips can be knife-like and therefore sufficiently thin to penetrate the ground. An at least partial lateral sealing is hereby realized. The distance from between the catching construction and the ground is preferably also adjusted using the wear strips. The distance between the catching construction and the ground can for instance thus be increased if it is found during use that the catching construction wears too quickly or is still in danger of becoming blocked. If desired, the catching construction according to the invention is provided with a series of jet pipes for ejecting a medium, for instance water, under pressure in order to fluidize the ground, break up and/or transport undesirable objects, or for other reasons. The jet pipes—and therefore also the outflowing jet—can here be directed toward the interior of the visor, for instance at the teeth, or be directed downstream, although it is also possible to provide jet pipes which are directed substantially vertically or almost vertically downward, all subject to the specific conditions of the ground for dredging.
The invention also relates to a method for breaking up and/or dredging at least partially hard grounds under water using a trailing suction hopper dredger equipped with a drag head according to the invention. The invented drag head makes it possible in simple manner to free the catching construction of undesirable objects should they nevertheless come to lie in the catching construction. The method comprises for this purpose a step in which the drag head is lifted from the bottom and/or in which the suction action is temporarily reduced or deactivated. Owing to the ingenious construction of the invention undesirable objects are here readily released from the catching construction. Obstructions can hereby be removed by simply interrupting the suction process, where this can seldom be achieved with a standard fixed catching structure. In this latter case the drag head must be brought back on board after a time in order to remove the obstructions manually. Since it is not necessary to do this with the catching construction according to the invention, the use thereof means a significant gain in dredging time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further elucidated with reference to the following figures and description of preferred embodiments, without the invention otherwise being limited thereto. In the figures:
FIG. 1 shows schematically a drag head of a trailing suction hopper dredger;
FIG. 2 shows a cross-section of a drag head according to the invention;
FIG. 3 is a bottom view of the drag head shown in FIG. 1 ;
FIG. 4 is a front view of a cross-section along line B-B of the drag head shown in FIG. 1 ;
FIG. 5 shows a perspective bottom view of a part of another embodiment of the visor of a drag head according to the invention;
FIG. 6 is a perspective bottom view of a detail of the embodiment variant shown in FIG. 4 ; and
FIG. 7 is a perspective bottom view of a part of the embodiment variant shown in
FIG. 4 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a drag head is shown which is moved in the direction of arrow P over a bottom for dredging by a trailing suction hopper dredger (not shown). The drag head comprises a visor 2 connected to a suction pipe 1 . Visor 2 is provided with, among other parts, side walls 3 , a rear wall 3 ′ and a top plate 4 with an arcuate part 5 which, when visor 2 rotates around rotation shaft 6 , remains in close contact with sealing strip 7 . The drag head rests with heel plate 8 on the bottom during dredging. If desired, heel plate 8 can be provided with a number of jet pipes 9 which inject water under pressure into the bottom for fluidization thereof. Downstream of heel plate 8 visor 2 is provided with a series of teeth 10 which are arranged on a toothed beam and which ensure that the ground is cut open. A second series of jet pipes 12 can optionally be arranged further downstream for the purpose of there also fluidizing the ground at greater depth. Jet pipes 12 are connected to a height-adjustable chamber 11 provided with water 13 . During dredging an underpressure is maintained inside suction pipe 1 and visor 2 by a suction pump (not shown), whereby the loosened soil particles are discharged through suction pipe 1 via suction opening 15 of visor 2 . For the purpose of proper lateral sealing thereof, visor 2 is preferably further provided with laterally running, knife-like wear strips 14 arranged on the underside of side walls 3 . Visor 2 is raised or lowered around rotation shaft 6 by means of hydraulic cylinder 16 . Cylinder 16 is connected fixedly relative to the drag head and is connected hingedly to rear wall 3 ′ of visor 2 by means of a hinge coupling 17 .
Referring to FIG. 2 , a first exemplary embodiment of a visor 2 of a drag head according to the invention is shown. Visor 2 is provided with a catching construction 20 for undesirable objects such as for instance large stones, rocks and/or bombs. In the shown variant catching construction 20 is received horizontally in visor 2 . This is not essential, and catching construction 20 can run at an angle to the underside of visor 2 , or even vertically. As can be clearly seen in FIG. 3 , catching construction 20 closes the suction opening with the exception of a number of passage openings 21 . What is exceptional about the invented catching construction 20 is that at least a number of passage openings 21 have a variable passage area. In the preferred embodiment shown in FIGS. 2 , 3 and 4 this is achieved as follows. Catching construction 20 comprises a framework of rods ( 22 , 23 ) which run crosswise and between which are situated passage openings 21 . Longitudinal rods 22 run in the length direction of visor 2 (during use this direction corresponds to the dragging direction P), while transverse rods 23 run in transverse direction of visor 2 . According to the invention at least some of the longitudinal rods 22 and/or transverse rods 23 are connected movably to visor 2 . Referring to the variant shown in FIG. 3 , the first series of rods connected fixedly to visor 2 is formed by longitudinal rods 22 a . Transverse rods 23 a are mounted movably between longitudinal rods 22 a and connected to the side of the visor. Longitudinal rods 22 a are for instance welded onto rear wall 3 ′ of visor 2 . In the variant shown in FIG. 3 the transverse rods 23 a are connected movably to side wall 3 and/or fixed longitudinal rods 22 a by means of a fixing slat 26 on which a locking slat 27 is mounted. A second series of longitudinal rods 22 b is connected movably to visor 2 , and more particularly to transverse rods 23 a of the first series. As shown in FIG. 2 , the coupling between longitudinal rods 22 b and transverse rods 23 a is formed by a coupling slat 22 c (shown by hatching) which is placed over transverse rods 23 a and which is provided with openings 22 d such that these can be placed over transverse rods 23 a . Movable longitudinal rods 22 b are then welded fixedly to the underside of coupling slat 22 c . It is also possible to apply a bolt connection for locking slat 27 . Such a connection makes the replacement of a possibly damaged longitudinal rod 22 b and/or transverse rod 23 a very simple. Openings 22 d in coupling slat 22 c ensure that it is slidable in transverse direction over transverse rods 23 a . Due to the play between openings 22 d and transverse rods 23 a a (possibly limited) downward or upward displacement (out of the plane of FIG. 3 ) is moreover possible. This makes longitudinal rods 22 b movable. Sleeves or spacer pipes 23 or end stops, between which coupling slats 22 c can slide, are arranged on the first series of rods 23 a in order to limit the movement.
It has been found that with catching construction 20 according to the invention significantly fewer undesirable objects become lodged in passage openings 21 . This is attributed to the above described ‘movable’ character of the catching construction. If, despite the improved operation, undesirable objects nevertheless are still left behind in the catching construction during dredging, a method in which the invented drag head is lifted and/or in which the suction action is temporarily reduced or deactivated is generally sufficient to free the catching construction of the undesirable objects. This saves a lot of production time. The increased mobility of the catching construction is evidently sufficient to once more shed objects in simple manner which are firmly lodged due to the strong suction action of the suction pipe. This is surprising since one would precisely expect an object lodged in the catching construction to counteract the mobility of the rods of the catching construction, whereby there would be no difference from a catching construction with only fixed rods.
FIG. 5 shows another preferred variant of the invented catching construction. A visor 2 with side walls 3 , a top plate 4 with arcuate portion 5 and a rear wall 3 ′ is shown. Visor 2 is provided on the downstream side with a toothed beam 18 which incorporates openings 10 ′ for teeth 10 for mounting. Visor 2 is provided on the inside with a number of strengthening partitions 40 , several of which are provided on the upstream side with openings 41 in which rotation shaft 6 (shown in FIGS. 1 and 2 ) can be received. Three transverse pipes 42 are received in side walls 3 of visor 2 . These are dimensioned such that they provide sufficient strength and rigidity for the visor and can also be provided with teeth or other cutting tool. A first series of transverse pipes 42 is received in openings 43 of partitions 40 . Movable coupling slats 44 are further received on transverse pipes 42 between fixed partitions 40 . These slats are also provided with openings which are pushed over transverse pipes 42 . As shown in more detail in FIG. 6 , a second series of longitudinal rods 45 is fixed on the underside onto coupling slats 44 (for the sake of clarity longitudinal rods 45 are not shown in FIG. 5 ). Longitudinal rods 45 are thus connected movably to the first series of transverse pipes 42 by means of a slidable coupling 44 . The sliding can take place to limited extent between two end stops 46 arranged on the first series of transverse pipes 42 . Catching construction 20 comprises the framework formed by rods 42 and 45 which run crosswise and between which passage openings 21 are situated.
FIG. 7 shows a further preferred variant in which all partitions 40 are provided with fixed longitudinal rods 45 a and coupling slats 44 with movable longitudinal rods 45 . Toothed beam 18 of the drag head is moreover provided with a first series of teeth 10 . Transverse pipes 42 of catching construction 20 are likewise provided with a second series of teeth 50 .
The invention is not limited to the above described embodiments and also comprises modifications thereto to the extent these fall within the scope of the appended claims. | A drag head of a trailing suction hopper dredger. The drag head comprises a rotatable visor connected to a suction pipe for discharging soil via the suction opening of the visor, wherein the visor is provided with a catching construction for undesirable objects. The catching construction closes the suction opening except for passage openings, wherein at least a number of passage openings have a variable passage area. A method for breaking up and/or dredging at least partially hard grounds under water using a trailing suction hopper dredger equipped with a drag head. | 4 |
TECHNICAL FIELD
[0001] This invention relates generally to cotton seed cleaners, and more particularly to an improved apparatus for cleaning cotton seeds prior to subsequent processing.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] Cotton seeds are used in numerous industrial and consumer applications. Cleaned seeds are processed into cottonseed vegetable oil for cooking applications and cottonseed meal for livestock and poultry feed. The byproducts removed during the cleaning of cotton seeds also have several industrial and commercial uses; for example, the hulls are used as roughage for livestock feed and the lint removed is used in several industrial and commercial products.
[0003] Referring to FIG. 1 of the drawings, there is shown a conventional cotton seed cleaner 10 , comprising a four shaker-tray system. Debris is removed as the seeds drop down through the shaker-trays 12 , 14 , 16 and 18 . As the seeds are fed into the shaker tray system, a deflector 19 divides and guides the seeds onto the trays. Larger debris such as sticks, rocks, paper, wood, etc. is removed as the seeds drop through the orifices in the top tray 12 . Smaller debris such as loose meats, small stones, small shale, and the like are removed as the seeds drop through the orifices in the second tray 14 . Similarly, larger debris items are removed as the seeds fall through the orifices in the third tray 16 , and the smaller trash and debris is removed in the bottom tray 18 . Once the seeds have passed through the trays and fall through the orifices in the second tray 14 and the bottom tray 18 , they are cleaned and ready for processing into commercial and industrial products such as cottonseed oil and livestock feed.
[0004] Lint and light shale are removed at each of the four shaker trays along with the other debris, but because of the light weight of the lint and shale, they do not progress down the trays for sorting and further processing as efficiently as the larger, heavier debris. Instead, the lint and light shale get trapped in the orifices at the bottom of the trays, eventually blinding and clogging the orifices altogether and preventing any seed from falling through, thereby lessening the efficiency and speed of the cotton seed cleaner 10 . As a result, the cotton seed cleaner 10 must be cleaned and maintained frequently which reduces the efficiency and speed of production, ultimately increasing the cost of production. In addition to the production cost, the trapped lint results in lost profits which could have been realized from the sale of the lint. Further the lint recovered by unclogging the orifices for sale as a byproduct is a lesser quality, less valuable lint byproduct because it has been handled more than the lint removed off of the shaker trays.
[0005] The present invention comprises a cotton seed cleaner which overcomes the foregoing and other difficulties which have long since characterized the prior art. In accordance with the broader aspects of the invention, a cotton seed cleaner comprises an initial air wash which removes lint before the seed enters into a cascading shaker tray and subsequent pin mill drum system.
[0006] Following the initial air wash, seeds enter a shaker tray system. The shaker tray comprises a plurality of cascading trays which scalps the larger debris and trash from the seeds. Once the larger debris is removed through the shaker tray system, the seeds enter a pin mill drum system, where the seeds are completely fluffed and cleaned of the smallest debris and any embedded hull trash.
[0007] Because the lint is removed prior to the seeds entering the shaker trays, the trays are less likely to become clogged with debris, therefore reducing the cleaning and maintenance frequency of all components of the cotton seed cleaner. The cascading shaker trays more effectively remove the larger debris so that when the seeds enter the pin mill system, the only debris remaining on the seeds is the smallest debris and any embedded hull trash. As the seeds proceed through a plurality of pin mill drums, the seeds are fluffed and any remaining debris is removed from therefrom. The smaller lint is then sorted by a vibrating table, where the smaller lint is sorted further and collected for further processing. Not only does the cleaning method of the present invention improve the efficiency and effective of the cleaner, but also enables better collection and sorting of the debris for further processing and sale.
[0008] The cotton seed cleaner of the present invention produces cleaner seeds and better byproducts, increasing revenue realized from both the cleaned seeds and the byproducts. In addition to the increased revenue from the sale of raw goods, the decrease in maintenance and cleaning frequencies reduces the operating cost, which positively impacts revenue gains.
BRIEF DESCRIPTION OF THE DRAWING
[0009] A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein:
[0010] FIG. 1 is an illustration of a prior art cottonseed cleaner;
[0011] FIG. 2 is an illustration of the preferred embodiment of the present invention;
[0012] FIG. 3 is similar to FIG. 2 showing the apparatus of the present invention in use;
[0013] FIG. 4 is an enlarged view of one portion of the apparatus shown in FIG. 2 ;
[0014] FIG. 5 is an enlarged view of another portion of the apparatus shown in FIG. 2 ;
[0015] FIG. 6 is an enlarged view of yet another portion of the apparatus shown in FIG. 2 ; and
[0016] FIG. 7 is an enlarged view of yet another portion of the apparatus shown in FIG. 2 .
DETAILED DESCRIPTION
[0017] Referring now to the Drawings, and particularly to FIGS. 2 and 3 thereof, there is shown a cotton seed cleaner 20 incorporating the present invention. Dirty seeds are fed into the cleaner 20 through a metered feeder 22 . The seeds fall through a vertical chute 24 and onto a shaker deck 26 containing a series of cascading shaker trays 28 . As seeds fall down through the vertical chute 24 , an airwash removes the majority of fly lint from the seeds and is extracted through a discharge duct 30 .
[0018] At the bottom of the vertical chute 24 the substantially lint free seed travels down the series of cascading shaker trays 28 . As the seeds progress down the cascading trays 28 , large debris such as sticks, stems, cotton tufts, grabbots, and the like are scavenged off and fall into a discard chute 32 for collection and further processing. Having the larger debris removed, the seeds fall through perforated shaker trays 28 onto a slide 34 . The seeds then fall off the end of the slide 34 into a housing 36 comprising a series of pin mill drums 38 . Seeds progress through the pin mill drums 38 which remove any remaining debris. The remaining debris is discarded onto a vibrating table 40 located below the pin mill drums 38 where the debris is sorted further and carried into debris collection bins 42 located at the bottom of the discard chute 32 for extraction and further processing. After complete cleaning by pin mill drums 38 the seeds enter a collection chute 44 and fall into a clean seed collection bin 46 to await packaging or further processing.
[0019] As is best shown in FIG. 4 , the seeds enter the vertical chute 24 through a metered feeder 22 . A feeder motor 50 provides the power for the metered feeder 22 . Located at the bottom of the metered feeder 22 is a spring-loaded panel 52 which prevents large debris such as concrete chunks, large rocks, scrap metal, and the like from entering into the cleaner 20 . When the panel 52 catches a large debris item the metered feeder 22 pauses and triggers an alarm to alert an operator to remove the large debris item.
[0020] Located below the inlet of the vertical chute 24 is a removable plate magnet 54 which catches ferric debris thereby preventing it from continuing into the cleaning process. As the seeds fall down the vertical chute 24 a suction fan located at the end of a discharge duct 30 creates a counter-current airwash in the vertical chute 24 for removing fly lint and the lightest debris from the seeds. The lint and other light debris is removed through the discharge duct 30 for collection and further processing. The suction fan creating the airwash is sized according to the size of the cotton seed cleaner 20 . For example, a cotton seed cleaner 20 comprising a vertical chute 24 having a diameter of 16 to 18 inches requires a 6500 CFM fan.
[0021] The vertical chute 24 is formed with two inclined panels 56 . The inclined panels 56 help to break up any clumps or large wads of seeds so the seeds reach the shaker deck 26 in a more atomized and loose formation. Located at the bottom of the vertical chute 24 is a gate 58 which may be manually adjusted vertically to regulate the seed flow into the shaker deck 26 . Two inspection windows 59 are located on the vertical chute for inspection of the seedflow therethrough.
[0022] FIG. 5 illustrates the seeds progressing through the shaker deck 26 . The shaker trays 28 are fabricated from metal and have perforated top surfaces. The shaker trays 28 may also be fabricated from other rigid materials known to those skilled in the art and commonly used in the food processing industry. The perforations in the top surfaces of the shaker trays 28 are sized to allow only seeds to fit through. The preferred size of the perforations of the upper shaker trays 28 at the top of the shaker deck 26 is ⅝ inch +/−10%. The remaining shaker trays 28 have ¾ inch +/−10% sized perforations in the top surfaces thereof. As a result, the larger debris is scavenged from the seeds and the clean seeds fall through the perforations of the trays 26 onto the slide 34 .
[0023] The shaker deck 26 is supported by angle irons 60 and leaf springs 62 . The shaker trays 26 are agitated by an arm 64 , which is oscillated by an eccentric 66 secured to a drive shaft 68 driven by a motor 70 . The arm 64 threads into the eccentric 66 and is secured in place by a nut. The preferred embodiment comprises a shaker deck 26 vibrated a frequency of 500-550 RPM. The larger debris falls through the chute 32 to the debris collection bins 42 below. Any small or loose debris that does not fall into the collection bins 42 is carried away by a suction airwash into a duct 72 . The airflow through the duct 72 is regulated by a damper 74 controlled by a handle 76 located above the debris collection bins 42 . The preferred embodiment comprises a duct 72 having a diameter of 6 inches, requiring an airflow of 750 CFM.
[0024] At the end of the slide 34 the seeds continue into the housing 36 containing the series of pin mill drums 38 . Referring specifically to FIG. 6 , the series of pin mill drums 38 is driven by a belt 78 turned by a motor 80 . A timing drive connects all of the pin mill drums 38 and causes all the pin mill drums 38 to rotate in the same direction, at a preferred rotation of 300-350 RPM.
[0025] Encased in each pin mill drum 38 is a wheel 82 with pins 84 protruding therefrom. The pins 84 fluff the seeds and loosen any remaining debris. The preferred embodiment comprises pins 84 which are ⅜ inch in diameter. Below each pin mill drum 38 are drawers 86 with perforated bottom surfaces. These drawers 86 may be fabricated from metals or other rigid materials known to those skilled in the art and suitable for use in the food processing industry. The perforations in bottom surface of the drawers 86 are sized to prevent seed from passing through and allowing only debris sized smaller than the seeds to pass through. The preferred size of the perforations in the bottom of drawers 86 is 3/16 to 5/16 inch +/−10%.
[0026] As is best shown in FIG. 7 the smaller sized debris falls through the perforated bottom surface of the drawers 86 onto the vibrating table 40 located below the pin mill drums 38 . The vibrating table 40 has a perforated surface and vibrates at a very high frequency, short stroke vibration, preferably 650-680 RPM. The vibrating table is vibrated by an arm 92 which is oscillated by an eccentric 94 on a small drive shaft 96 controlled by a motor 98 . The perforations of the vibrating table 40 are sized to sort the small debris which has fallen from the pin mill drums 38 . The preferred size of the perforations of the vibrating table 40 is 1/16 to ⅛ inch +/−10%. The smallest debris such as bran, sand, and dirt fall through the vibrating table 40 and onto a bottom chute 90 which carries the debris to the debris collection bins 42 . The vibrating table 40 and bottom chute 90 are supported by a plurality of angle irons 100 and leaf springs 102 .
[0027] When the seeds reach the end of the series of pin mill drums 38 they are completely clean of debris. Any remaining lint or loose debris that did not fall through the drawers 86 going through the pin mill drums 38 is separated and pulled into a vertical discharge duct 104 by an airwash caused by the same suction fan that created the airwash is the vertical chute 24 . The suction airflow into the vertical discharge duct 104 is regulated by a damper 106 controlled by an external handle 108 . The preferred embodiment comprises a discharge duct 104 having a diameter of 10 inches, requiring an airflow of 1200 CFM. The completely cleaned seeds fall through the collection chute 44 and into a clean seed collection bin 46 for packaging and/or further processing.
[0028] Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention. | A cotton seed cleaner includes an initial airwash, a shaker deck with a series of cascading shaker trays, and a plurality of pin mill drums for more efficient and thorough cleaning of seeds to be used in industrial and commercial products. The result is a more efficient and cost effective cleaning process of the seeds, yielding cleaner seed and more quality byproducts for use in commercial and industrial products. | 3 |
FIELD
[0001] An embodiment of the invention relates to a recessed lighting unit that is mounted behind a ceiling or a wall via its interface module. Other embodiments are also described.
BACKGROUND
[0002] Recessed lighting units are typically installed or mounted to a structural member of a dwelling behind a ceiling or a wall. Recessed lighting units generally consist of various components of different shapes and sizes. For example, different styles of trims and light source modules may be used to accommodate different needs of consumers.
[0003] Although current recessed lighting units come in a variety of shapes and sizes, switching between different components can be tedious and cumbersome. In particular, current systems require the removal of numerous screws and fasteners to change a single component of the system, such as a trim. Thus, there is a need for a lighting system that enables efficient interchangeability between different components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one.
[0005] FIG. 1 shows a side view of a recessed lighting unit and its components positioned partly inside a ceiling or a wall, including an interface module, lighting trim, heat sink, wire connector assembly, electrical wires, power source, and flexible conduit according to one embodiment.
[0006] FIG. 2 shows a cross-section view of a recessed lighting unit and its components positioned partly inside a ceiling or a wall, including an interface module, lighting trim, heat sink, and light source module, according to one embodiment.
[0007] FIG. 3 shows a perspective view of the interface module according to one embodiment.
[0008] FIG. 4 shows an overhead view of the interface module according to one embodiment.
[0009] FIG. 5 shows a side view of the interface module according to one embodiment.
[0010] FIG. 6 shows a perspective view of an interface module according to another embodiment.
[0011] FIG. 7 shows an overhead view of the interface module according to another embodiment.
[0012] FIG. 8 a shows a side view of the interface module according to another embodiment.
[0013] FIG. 8 b shows a cross section view of the interface module according to another embodiment.
[0014] FIG. 9 shows two perspective views of female component of a wire connector assembly according to one embodiment.
[0015] FIG. 10 shows a cross-section view of the female component of a wire connector assembly according to one embodiment.
[0016] FIG. 11 shows two perspective views of a male component of the wire connector assembly according to one embodiment.
[0017] FIG. 12 shows a cross section view of the wire connector assembly according to one embodiment.
[0018] FIG. 13 shows two perspective views of a two-piece female component of a wire connector assembly according to another embodiment.
[0019] FIG. 14 shows two cross-section views of a two-piece female component of a wire connector assembly according to another embodiment.
[0020] FIG. 15 shows two perspective views of a male component of the wire connector assembly according to another embodiment.
[0021] FIG. 16 shows a cross section view of the wire connector assembly according to another embodiment.
[0022] FIG. 17 shows a side view of the male component of the wire connector assembly according to another embodiment.
[0023] FIG. 18 shows a cross section view of a snap-on lighting trim assembly and its components, including an interface module, lighting trim, flexible retainer ring, and a reflector.
[0024] FIG. 19 an overhead view, a side view, and a perspective view of a flexible retainer ring according to one embodiment.
[0025] FIG. 20 shows a side view of a lighting trim with a recessed base and a retaining edge, according to one embodiment.
[0026] FIG. 21 shows a side view of a lighting trim with a recessed base and a notch, according to another embodiment.
DETAILED DESCRIPTION
[0027] Several embodiments are described with reference to the appended drawings are now explained. While numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description.
[0028] A recessed lighting unit 1 is disclosed. FIG. 1 shows a side view of one embodiment of a recessed lighting unit 1 that is positioned on a ceiling or wall 2 to provide light into a room. The recessed lighting unit 1 may have an interface module in the form of a housing 3 that is coupled to a lighting trim 4 , heat sink 5 , and a wire connector assembly 6 that is engaged to a through-duct 7 of the housing 3 . The lighting trim 4 of the recessed lighting unit 1 may cover the exposed edge of an opening or hole in the ceiling or wall 2 . The lighting trim 4 helps the recessed lighting unit 1 to appear seamlessly integrated into the ceiling or wall 2 . The housing 3 may be formed so that it may be coupled to lighting trims 4 of different sizes. The housing 3 serves to house a light source module 10 (shown in FIG. 2 ) while allowing light from the light source module 10 to be emitted into a room through the opening in the ceiling or wall 2 .
[0029] FIG. 1 also shows a magnified cross-section view of an electrical wire 8 a which may be connected to a power source 9 that provides electricity. The power source 9 (which may include an electronic power supply circuit) is designed to ensure that the appropriate voltage and current are fed to the light source module 10 to enable the emission of light by the one or more light sources within the light source module 10 . In one embodiment, an AC to DC power conversion module with a 120 Volt AC input may be used whose input is connected to the AC wiring that is between the walls 2 or between a ceiling 2 and a floor in a dwelling (not shown). In one embodiment, the AC to DC power conversion module can be integrated as part of the light source module 10 .
[0030] The electrical wire 8 a may be surrounded by a flexible conduit 11 . There may be one or more insulating layers in between the electrical wire 8 a and the flexible conduit 11 . The electrical wire 8 a may be led through the flexible conduit 11 and attached to one or more electrical contacts at the end of the flexible conduit 11 . In one embodiment, flexible conduit 11 with electrical wire 8 a may be a coaxial cable with one or more electrical contacts attached to its end, forming a coaxial connector 56 a.
[0031] The flexible conduit 11 with one or more electrical contacts that forms a coaxial connector 56 a may be engaged to the wire connector assembly 6 (which may have a female component 22 and a male component 23 , discussed in further detail below). A top end of the wire connector assembly 6 may have an electrical wire 8 b attached to a coaxial connector 56 b . The electrical wire 8 b may be surrounded by an insulating layer. The electrical wire 8 b may be connected to the light source module 10 located inside the housing 3 . The electrical wire 8 b may be led from the light source module 10 through a hollow interior of the wire connector assembly 6 and through the through-duct 7 of the housing 3 . When the flexible conduit 11 is engaged or coupled to wire connector assembly 6 , the electrical contacts of both electrical wires 8 a and 8 b would come into contact as the coaxial connectors 56 a and 56 b are engaged. The electrical contact of the electrical wire 8 a attached to the flexible conduit 11 may be male or female, as long as it is complementary to the electrical contact of the electrical wire 8 b attached to the wire connector assembly 6 .
[0032] FIG. 2 shows a cross-section view of the recessed lighting unit 1 that is positioned on a ceiling or wall 2 . The recessed lighting unit 1 has a housing 3 , lighting trim 4 , heat sink 5 , and light source module 10 . The light source module 10 may include any electro-optical device or combination of devices for emitting light. For example, the light source module 10 may have as a single light source a light emitting diode (LED), organic light-emitting diode (OLED), or polymer light-emitting diode (PLED) installed on a carrier structure (e.g., a printed circuit board or flex circuit). In some embodiments, the light source module 10 may have multiple light sources (e.g., LEDs, OLEDs, and/or PLEDs). The light source module 10 receives electricity from a power source 9 such that the light source module 10 may emit a controlled beam of light into a room or a surrounding area. In one embodiment, the light source module 10 may include a set of electrical leads positioned in its carrier structure, for receiving electricity from the power source 9 via electrical contacts. The electrical leads of the light source module 10 may be soldering points that are traditionally coupling areas for electrical wires 8 b that are directly soldered to the light source module 10 and directly connect the light source module 10 with the power source 9 . The light source module 10 may be surrounded by a light reflector 55 (shown in FIG. 18 ) to direct the beam of light in the desired direction.
[0033] FIGS. 3-5 show a perspective view, an overhead view, and a side view of one embodiment of an interface module in the form of a housing 3 . As shown in FIG. 3 , the interface module is a housing 3 in which a top opening 12 and a bottom opening 13 are formed in an outer surface 14 of the housing 3 , wherein the top 12 and bottom 13 openings are open to a cavity 15 . Cavity 15 is defined in part by an inner surface 16 of the housing 3 . One or more screw holes 17 may be positioned on the housing 3 so that they are accessible through the top opening 12 or bottom opening 13 , which may receive screws for attaching a heat sink 5 , for example, to the housing 3 .
[0034] FIG. 3 also shows the housing 3 having a through-duct 7 formed thereon, which may allow connection of an electrical wire 8 a from a power source 9 located outside of the housing 3 to an electrical wire 8 b connected to a light source module 10 located inside of the housing 3 . Connection of electrical wires 8 a and 8 b may be accomplished via a wire connector assembly 6 as described above. Through-duct 7 may be engaged to a wire connector assembly 6 , i.e. a male component 23 and female component 22 (in embodiments where there is no female component 22 , as described below, the male component 23 may be referred to as a wire connector 23 ). Thus, the through-duct 7 allows the flexible conduit 11 to be secured to the housing 3 through a wire connector assembly 6 . As shown in FIG. 5 , the through-duct 7 has a first through-duct opening 18 in the outer surface 14 that leads to a second through-duct opening 19 in the inner surface 16 . The through-duct 7 forms a pathway between the first through-duct opening 18 in the outer surface 14 and the second through-duct opening 19 in the inner surface 16 . In one embodiment, the through-duct 7 may have an upper portion 20 and a lower portion 21 , between the first through-duct opening 18 and the second through-duct opening 19 . As shown in FIG. 3 and FIG. 5 , an embodiment of the housing 3 may have a lower portion 21 that forms an elbow between the upper portion 20 and the second through-duct opening 19 . In another embodiment, the pathway of the through-duct 7 need not have an elbow, and may be shaped to form a right circular cylinder, an oblique circular cylinder, or a polygonal tube. The pathway may have one or more bends. In the case of a right circular cylinder, the cylinder would be oriented horizontally relative to the housing 3 . In that case, it follows that the wire connector assembly 6 would also be positioned horizontally. Where the through-duct 7 is shaped as an oblique circular cylinder, shape of the wire connector assembly 6 may conform to the shape of the through-duct 7 .
[0035] FIGS. 3, 4 and 5 show an embodiment where the through-duct 7 forms a bulge or protrusion that extends outwardly. However, it is not necessary to have a bulge or protrusion formed on the outer surface 14 in order to form through-duct 7 . In another embodiment, outer surface 14 may be made with increased thickness so that through-duct 7 is subsumed by the outer surface 14 , allowing for a smooth or uninterrupted outer surface 14 without a bulge or protrusion. In another embodiment, outer surface 14 may have a greater circumference so that the through-duct 7 is formed inside of the circumference. In these embodiments, the shape of the interior of through-duct 7 , with its upper portion 20 and lower portion 21 , may remain the same.
[0036] In one embodiment, as shown in FIG. 3 , the first through-duct opening 18 and the upper portion 20 may be completely or partially enclosed. Also, top opening 12 may be completely or partially enclosed. FIG. 3 shows an embodiment where the first through-duct opening 18 and the upper portion 20 are partially enclosed. FIG. 3 also shows an embodiment where the top opening 12 and the first through-duct opening 18 are contiguous with each other. In another embodiment, the top opening 12 and the first through-duct opening 18 need not be contiguous with each other. The first through-duct opening 18 need not have the same height as the top opening 12 . The first through-duct opening 18 may be higher or lower than the top opening 12 , and may have an angle. Also, the through-duct 7 need not be strictly vertical at the upper portion 20 and may be formed at an angle.
[0037] FIGS. 6-8 b show another embodiment of housing 3 . For example, FIG. 6 shows the through-duct 7 having a first through-duct opening 18 in the outer surface 14 that leads to a second through-duct opening 19 in the inner surface 16 (as shown in FIG. 8 b ). FIG. 8 b also shows the through-duct 7 having an upper portion 20 and a lower portion 21 , between the first through-duct opening 18 and the second through-duct opening 19 . The lower portion 21 may form an elbow between the upper portion 20 and the second through-duct opening 19 . However, as described above, through-duct 7 need not have an elbow, and may be shaped to form a right circular cylinder, an oblique circular cylinder, or a polygonal tube. In this embodiment, the first through-duct opening 18 is completely enclosed. The top opening 12 is interrupted by the first through-duct opening 18 and through-duct 7 , but the top opening 12 and the first through-duct opening 18 are not contiguous with each other like the embodiment shown in FIGS. 3-5 .
[0038] As described above, the through-duct 7 may provide a pathway for the electrical wire 8 b that is led from the light source module 10 inside of the cavity 15 of the housing 3 to connect with electrical wire 8 a led from the power source 9 . The connection of the electrical wires 8 a and 8 b are secured to the housing 3 by the wire connector assembly 6 being engaged to the through-duct 7 . The wire connector assembly 6 may have a female component 22 ( FIGS. 9 and 10 ) and a male component 23 ( FIGS. 11 and 12 ). The female component 22 and male component 23 form a twist and lock mechanism where the male component 23 is inserted into the female component 22 and twisted into a locked position. The first through-duct opening 18 is shaped so that it is capable of having the female component 22 of the wire connector assembly 6 positioned inside upper portion 20 . The female component 22 may be keyed into upper portion 20 so that the female component 22 does not easily fall out of the upper portion 20 . The female component 22 may also be attached to the upper portion 20 by glue, screws, snapping mechanism, and the like. Once the female component 22 is positioned inside the upper portion 20 , the male component 23 can be engaged to the female component 22 .
[0039] FIG. 9 shows two perspective views of female component 22 . FIG. 10 shows a cross section view of female component 22 . The female component 22 of a wire connector assembly 6 has an exterior surface 24 , an interior surface 25 , a top opening 27 , and a bottom opening 28 . FIG. 12 shows a cross-section view of the wire connector assembly 6 with the female component 22 and male component 23 engaged in a locked position through a twist and lock mechanism. The twist and lock mechanism is formed by the female component 22 having one or more locking engagements 26 formed on the interior surface 25 that are shaped to engage one or more locking members 30 formed on an exterior surface of the male component 23 . The male component 23 and female component are locked when the male component 23 is inserted into the female component 22 and turned about its longitudinal axis into a locked position. The locking member 30 and locking engagement 26 may have a variety of shapes, as long as they are formed to engage each other to form a locking mechanism.
[0040] The female component 22 may have one or more retaining surfaces 31 that abut one or more retaining lips 32 of a male component 23 of the wire connector assembly 6 when the male component 23 of the wire connector assembly 6 inserted into the female component 22 and is turned about its longitudinal axis into a locked position. The one or more retaining surfaces 31 may abut one or more of retaining lips 32 of the male component 23 of the wire connector assembly 6 when one or more of the locking engagements 26 are engaged to one or more of locking members 30 . The one or more retaining surfaces 31 need not always be in direct contact with the one or more retaining lips 32 . There may be a small gap in between the retaining surface 31 and retaining lip 32 . While there may be a small gap, when the male component 23 is pulled upwards while in a locked position, the retaining lip 32 would contact the retaining surface 32 and prevent the male component 23 from being pulled out. In order to pull out the male component 23 , one must twist the male component 23 to unlock it from the female component 22 by twisting it longitudinally into an unlocked position.
[0041] FIG. 11 shows two perspective views of the male component 23 of the wire connector assembly 6 , according to one embodiment. The male component 23 of the wire connector assembly 6 has a top end with an opening 29 and a bottom end with an opening 33 , and a hollow interior 34 running longitudinally from the top end to the bottom end. While not shown in FIG. 11 , there may be an electrical wire 8 b attached to the top opening 29 of the male component 23 that forms a coaxial connector 56 b , as described above. The male component 23 has one or more retaining lips 32 that extend outwardly from the bottom end. The male component 23 also has a grip section 35 formed on the exterior surface of the male component 23 of the wire connector assembly 6 between the top end and the bottom end. The grip section 35 may have one or more knurls 36 that provide friction for a user to twist the male component 23 by hand without the need for tools. While the use of knurls 36 is one way to provide friction, knurls 36 are not absolutely necessary, as there are other ways of providing friction. The grip section 35 may have ridges, sawtooth surface, or the like, that provide friction for a user's fingers. The male component 23 has one or more locking members 30 on the lower exterior surface 40 of the male component 23 of the wire connector assembly 6 between the grip section 35 and the bottom end. The locking members 30 , as explained above, may engage to locking engagements 26 of the female component 22 .
[0042] Once the bottom end of the male component 23 is inserted into a top opening 27 of the female component 22 so that the retaining lips 32 pass beyond the bottom end of the female component 22 , the male component 23 may be twisted by hand by gripping the grip section 35 . Because the retaining lips 32 of the male component 23 must pass beyond the bottom end of the female component 22 (as shown in FIG. 12 ), it is preferred that there be free space below the bottom end of the female component 22 inside the through-duct 7 . This free space allows the retaining lips 32 of the male component 23 to turn freely inside the through-duct 7 when the male component 23 is turned about its longitudinal axis. Once turned, one or more locking members 30 on the male component 23 engage one or more locking engagements 26 . Also, one or more retaining lips 32 of the male component 23 abuts one or more retaining surfaces 31 at the bottom end of the female component 22 . For example, when the male component 23 is inserted into the top opening 27 of the female component 22 and is turned clockwise or counterclockwise approximately 90 degrees, the one or more retaining lips 32 abut the one or more retaining surfaces 31 . This prevents the male component 23 from falling out or pulled out of the female component 22 once the wire connector assembly 6 is in locked position. As stated above, the one or more retaining surfaces 31 need not always be in direct contact with the one or more retaining lips 32 .
[0043] In another embodiment (not shown in the figures), the need for a separate female component 22 may be eliminated by providing for the same or similar features of the female component 22 on the upper portion 20 of the though-duct 7 itself In this embodiment, the male component 23 may simply be referred to as a wire connector 23 . Like the female component 22 , upper portion 20 may have one or more locking engagements 26 formed on the interior surface 25 of the upper portion 20 that are shaped to engage one or more locking members 30 formed on an exterior surface of the wire connector 23 when the wire connector 23 is inserted into the upper portion 20 and turned about its longitudinal axis into a locked position. The upper portion 20 may have one or more retaining surfaces 31 that abut one or more retaining lips 32 of the wire connector 23 when the wire connector 23 is inserted into the upper portion 20 and is turned about its longitudinal axis into a locked position. The one or more retaining surfaces 31 may abut one or more of retaining lips 32 of the wire connector 23 when one or more of the locking engagements 26 are engaged to one or more of locking members 30 . Within the upper portion 20 of the through-duct 7 , there may be free space below the retaining surface 31 of the upper portion 20 of the through-duct 7 . The free space allows for the one or more retaining lips 32 of the wire connector 23 to turn freely inside the through-duct 7 when the wire connector 23 is turned about its longitudinal axis.
[0044] FIGS. 13-17 show another embodiment of wire connector assembly 6 having a female component 22 and male component 23 . FIGS. 13-14 show another embodiment of female component 22 , where the one or more retaining surfaces 31 that abut one or more retaining lips 32 of the male component 23 (shown in FIGS. 15 and 16 ) are not at the bottom end of the female component 22 . Instead, the one or more retaining surfaces 31 are positioned below the top opening 27 within the female component 22 . In addition, a gap 37 is within the interior of the female component 22 below the one or more retaining surfaces 31 , which provides free space for the retaining lips 32 to move within the female component 22 . The top opening 27 of the female component 22 may be elongated in shape to allow the one or more retaining lips 32 to pass through the top opening 27 . In this embodiment, the female component here does not have locking engagements 26 as shown in the embodiment depicted in FIGS. 9 and 10 . As shown in FIGS. 13 and 14 , the female component 22 may be made from two separate pieces 22 a and 22 b that can be combined into a single piece 22 . Female component 22 (pieces 22 a and 22 b ) may be held together by a snapping mechanism, glue, or the like.
[0045] FIG. 15 shows a male component 23 that corresponds to the female component 22 shown in FIGS. 13-14 . The one or more retaining lips 32 are not at the bottom end of the male component 23 , but in between the grip section 35 and the bottom end. In addition, the male component 23 does not have locking members 30 in between the grip section 35 and the bottom end of the male component 23 . In other respects, the male component 23 shown in FIG. 15 is similar to that shown in FIG. 11 .
[0046] FIG. 16 shows a cross section view of wire connector assembly 6 with the male component 23 (shown in FIG. 15 ) inserted into the female component 22 (shown in FIGS. 13 and 14 ) and placed in a locked position. When the bottom end of the male component 23 is inserted into the top opening 27 of the female component 22 , the one or more retaining lips 32 of the male component 23 passes below the one or more retaining surfaces 31 of the female component 22 . Below the retaining surface 31 , the female component 22 has a gap 37 that provides sufficient space for the one or more retaining lips 32 of the male component 23 to turn freely inside the female component 22 when the male component 23 is turned about its longitudinal axis. Once the one or more retaining lips 32 of the male component 23 pass below the one or more retaining surfaces 31 of the female component 22 into the gap 37 and the male component 23 is turned about its longitudinal axis, the one or more retaining lips 32 of the male component 23 abuts one or more retaining surfaces 31 . For example, when the male component 23 is inserted into the top opening 27 of the female component 22 and is turned clockwise or counterclockwise approximately 90 degrees, the one or more retaining lips 32 abut the one or more retaining surfaces 31 . In this locked position, the male component 23 cannot be easily pulled out of the female component 22 . As mentioned above, in the embodiment shown in FIGS. 13-17 , the female component 22 does not have one or more locking engagements 26 and the male component 23 does not have one or more locking members 30 .
[0047] The upper exterior surface 39 of the male component 23 (or wire connector 23 ) may have multiple rounded threading bumps 38 that may be threaded into a flexible conduit 11 . The flexible conduit 11 may have threads on its interior surface that have a corresponding pitch in relation to the rounded threading bumps 38 . FIG. 17 shows a side view of the male component 23 or wire connector 23 according to one embodiment. In between the top end of the wire connector 29 and grip section 35 , there are multiple rounded threading bumps 38 on the upper exterior surface 39 of the wire connector 23 . As shown in FIG. 17 , in one embodiment, a first set 41 ( a, b, c ) of rounded threading bumps 38 are positioned longitudinally along the upper exterior surface 39 of the wire connector 23 . There is also a second set 42 ( a, b, c ) of rounded threading bumps 38 positioned longitudinally along the exterior surface 39 of the wire connector 23 . The number of threading bumps may vary. The rounded threading bumps 38 of the first set 41 and the second set 42 are on opposite sides of a longitudinal cross section plane of the wire connector 23 . The longitudinal distance between one rounded threading bump 41 a and the next rounded threading bump 41 b , for example, of the first set 41 represents a pitch distance of a thread. Similarly, the longitudinal distance between one rounded threading bump 42 a and the next rounded threading bump 42 b of the second set 42 represents a pitch distance of a thread. The height difference between the rounded threading bumps 38 of the first set 41 and the second set 42 is half of the pitch distance. This allows the wire connector 23 or male component 23 to be twisted into a flexible conduit 11 that has threads of a corresponding pitch distance. The embodiment shown in FIG. 11 may have the same arrangement of threading bumps. In another embodiment, as shown in FIG. 1 , there may be multiple subsets of two threading bumps (instead of one threading bump) that conform to the thread on the interior surface of the flexible conduit 11 .
[0048] A snap-on lighting trim assembly for a recessed lighting unit 1 is also disclosed. FIG. 18 shows a cross section view of the snap-on lighting trim assembly including a housing 3 , flexible retainer ring 43 , a reflector 55 , heat sink 5 , and a lighting trim 4 . The housing 3 in which a top opening 12 and a bottom opening 13 are open to a cavity 15 . The cavity 15 may be defined in part by an inner surface 16 of a vertical sidewall of the housing 3 , wherein at least a portion of the inner surface 16 is cylindrical. Near the bottom portion of the housing 3 , there is an indentation 48 along the circumference of a horizontal cross-section plane of the inner surface 16 . The indentation 48 is capable of having a flexible retainer ring 43 positioned therein.
[0049] FIG. 19 shows an overhead view, a side view, and a perspective view of a flexible retainer ring 43 according to one embodiment. The flexible retainer ring 43 is a part of a snap-on lighting trim assembly. The flexible retainer ring 43 is used for coupling a lighting trim 4 to an interface module housing 3 without the need for screws, adhesives, or tools. The flexible retainer ring 43 has alternating arcuate sections 44 and linear sections 45 , and two arcuate ends 46 , wherein the flexible retainer ring 43 generally forms an incomplete circle on a plane. The flexible retainer ring 31 may be resilient and made of metal or polymer. The flexible retainer ring 43 is positioned inside the indentation 48 of the housing 3 before the lighting trim 4 is engaged.
[0050] FIG. 20 shows a side view of the lighting trim 4 of the snap-on lighting trim assembly according to one embodiment. The lighting trim 4 has a recessed base 49 that forms a closed curve, wherein an external surface of the recessed base 49 has a retaining edge 50 extending radially outward along a circumference of a horizontal cross-section plane of the recessed base 49 . While the flexible retainer ring 43 is positioned in the indentation 48 of the housing 3 , the recessed base 49 of the lighting trim 4 is inserted into the bottom opening 13 of the housing 3 . The flexible retainer ring 43 bends to allow the recessed base 49 into the bottom opening 13 until the retaining edge 50 passes the flexible retainer ring 43 . Because the flexible retainer ring 43 may be resilient, the linear sections 45 may approximately return to its original shape and contact the retaining edge 50 at its bottom, and prevent the lighting trim 4 from being pulled out of the housing 3 . It is understood that the flexible retainer ring 43 need not return to its exact original shape while holding the lighting trim 4 in place. No tools are required to engage the lighting trim 4 to the housing 3 .
[0051] In another embodiment, there may be a lighting trim assembly 1 with a twist and lock mechanism. FIG. 21 shows a side view of one embodiment of lighting trim 4 . Lighting trim 4 may have a recessed base 49 that has a notch 51 with a vertical opening portion 52 and a horizontal opening portion 53 . As shown in FIG. 8 a , housing 3 may have a side tab 54 extending outwardly from the exterior surface of the housing 3 that is shaped to engage a notch 51 on a lighting trim 4 . The lighting trim 4 is capable of being engaged to the housing 3 by inserting the side tab 54 into the vertical opening portion 52 and twisting the lighting trim 4 so that the side tab 54 is inserted into the horizontal opening portion 53 into a locked position. FIG. 1 shows a lighting trim assembly 1 with the lighting trim 4 engaged to a housing 3 with the twist and lock mechanism in a locked position.
[0052] While certain embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. The description is thus to be regarded as illustrative instead of limiting. | A recessed lighting unit for mounting to a ceiling or a wall is provided. The recessed lighting unit includes an interface module having a through-duct. The through-duct may be coupled to a wire connector assembly to secure an electrical wire to the interface module and allow the electrical wire to reach a light source module. The wire connector assembly may be twisted and locked to the interface module without the use of tools. The lighting trim may be snapped on to an interface module through the use of a flexible retainer ring. The lighting trim may also be twisted and locked to an interface module without the use of tools. The present invention provides for a reduced set of components while ensuring adaptability and easy installation of lighting units. Other embodiments are also described and claimed. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to processes for removing solvents from solvent laden air streams, and more particularly to processes for removing halogenated hydrocarbons and other solvents from solvent laden air streams.
2. Description of the Prior Art
The release of halogenated hydrocarbons into the atmosphere has drawn increasing attention from the scientific community as evidence gathers that the accumulation of these compounds in the atmosphere can adversely affect the earth's ozone layer. Governments have been increasingly conscious of controlling the emission of these compounds, particularly fluorocarbons, from industrial plants. Processes have been developed in the past to remove halogenated hydrocarbons and other solvents from process emissions. These processes improve the purity of the emitted stream, but do not reach the level of purity necessary to satisfy current environmental control demands.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a process for removing halogenated hydrocarbons and other solvents from a solvent laden air stream.
It is another object of the invention to provide a process which will provide an effluent stream of sufficient purity to satisfy environmental control demands.
It is still another object of the invention to provide a process for removing halogenated hydrocarbons and other solvents from a solvent laden air stream in which process components can be regenerated without significant emissions of contaminants.
These and other objects are accomplished by a cyclic process for removing solvents including halogenated hydrocarbons from a solvent laden air (SLA) stream, including the steps of:
(a) pre-conditioning the SLA to remove particulates and to adjust conditions of temperature and relative humidity;
(b) passing the SLA through at least two activated carbon adsorption beds connected in series;
(c) regenerating at least one additional activated carbon adsorption bed, the regeneration comprising the steps of:
(i) passing a regenerating gas through the adsorption bed, the regenerating gas removing halogenated hydrocarbons and other solvents from the bed;
(ii) condensing the regenerating gas to form a liquid fraction having at least one solvent rich fraction and at least one solvent poor fraction;
(iii) returning non-condensibles to the SLA inlet stream of step (b);
(iv) passing the liquid fractions to process battery limits; and,
(d) returning the regenerated bed of step (c) to the series of adsorption beds of step (b), and removing at least one of the adsorption beds from the series of step (b) and regenerating this bed by the process of step (c).
Operation of the adsorption beds is preferably counter-current such that a bed regenerated in step (c) is returned to the adsorption series of step (b) as the last bed in the series of adsorption beds. The SLA flow is rerouted through the series such that the numerical position of the beds in the series is incremented upstream. Other beds in the series are moved sequentially one step further from the SLA inlet. The bed that occupied the first position of the beds in the series is removed for regeneration, after which it is returned to the series rotation as the last bed in the series.
The regeneration gas is preferably steam. The liquid fraction resulting from the condensation of step (c) (ii) is preferably processed to separate the solvent rich fraction from the solvent poor fraction. The solvent rich fraction is passed to process battery limits, and preferably to collection means. The solvent poor fraction is preferably processed further to remove solvents from this fraction. Non-condensibles from the processing step of the solvent poor fraction are passed to the SLA inlet stream of step (b) for re-contact with the carbon adsorption beds. The recovered solvents are passed to collection means.
Processing of the solvent poor fraction preferably comprises contacting the solvent poor fraction with air in an air contactor. Air leaving the contactor is passed to the SLA inlet stream of step (b) such that solvents removed by the air are re-contacted with the carbon adsorption bed.
The condensation of regeneration steam preferably includes a bulk vapor condensation step and a vent condensation step. The vent condensation step is adapted to condense non-condensibles leaving the bulk vapor condensation step. Non-condensibles from the vent condensation step are returned to the SLA inlet stream. Condensed liquid from the vent condensation step is passed to the separation step where the solvent rich liquid fraction is separated from the solvent poor liquid fraction.
The liquid fraction from the vapor condensation step will normally be at a higher temperature than the liquid fraction from the vent condensation step. It is preferable to equalize these temperatures prior to mixing with the liquid fraction from the vent condensation step for separation. This can be accomplished by lowering the temperature of the liquid fraction from the vapor condensation step by means of a heat exchange step.
The separation of the condensation products into a solvent rich fraction and a solvent poor fraction is preferably decantation. Vapor product from the decantation will normally contain some solvent and preferably is returned to the SLA inlet stream entering the adsorbers.
The adsorption step (b) preferably comprises passing the SLA through at least two adsorbers connected in series. A third adsorber is regenerated simultaneously while the other two are performing the adsorption step (b). The respective adsorbers can be alternated such that each adsorber is periodically regenerated while at least two other adsorbers are performing the adsorption step. More adsorbers in series are also possible, which would reduce the frequency of regeneration that is necessary. It is also possible to provide a battery consisting of sets of series adsorbers connected in parallel.
The SLA is preferably preconditioned before entering the adsorbers. The SLA is preferably passed through a guard filter means that is adapted to remove contaminants that otherwise might plug the activated carbon bed in the adsorbers. The guard filter means preferably comprises an activated carbon bed that is of a smaller volume than the beds in the adsorbers. This bed is periodically discarded when it has been substantially deactivated with contaminants. Filter means for particulates can also be provided. The temperature of the SLA inlet stream is preferably adjusted in a heat exchange step. The pressure of the SLA stream can also be adjusted in a SLA blower step.
Cooling the bed after regeneration with hot gas has been found to promote efficient adsorption of the solvents, and particularly the halogenated hydrocarbons, on the activated carbon. The gas stream can be selected from several suitable gases. Air is a preferable cooling gas because of its availability and attendant reduced operating costs. The cooling air stream leaving the adsorber can be passed to the SLA inlet stream such that residual solvents removed by the cooling air stream are recirculated to the carbon adsorption beds. The cooling gas is preferably subjected to a heat exchange step prior to passage through the adsorbers in the cooling step.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings embodiments which are presently preferred it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
FIG. 1 is a schematic diagram of a process according to the invention.
FIG. 2a is a schematic diagram of an adsorber series in a first flow configuration.
FIG. 2b is a schematic diagram of an adsorber series in a second flow configuration.
FIG. 2c is a schematic diagram of an adsorber series in a third flow configuration.
FIG. 3 is a schematic diagram of a solvent laden air pre-conditioning unit according to the invention.
FIG. 4 is a schematic diagram of a cooling air pre-conditioning unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There is shown schematically in FIGS. 1-4 a preferred process according to the invention. The solvent laden air (SLA) enters through an SLA inlet 10. The SLA is conveyed by a path 12 to an adsorption step 16. Purified air leaves the adsorbers through a path 20 and can, in the usual case, be vented through vent means 22.
The adsorption step 16 is accomplished by the utilization of adsorbers in series having activated carbon beds. The beds gradually accumulate adsorbed halogenated hydrocarbons and other solvents and must be regenerated. The bed of activated carbon is preferably regenerated when desorption equilibrium is attained or nearly, that is, when the rate of contaminant particles that are adsorbed by the bed is matched or nearly matched by the rate of particles that leaves or passes the bed. Regeneration begins with closure of the paths 12 and 20 such by valve means 24 and 28, respectively. Valve means 32 are opened to permit steam from a steam supply 36 to traverse path 38 into the adsorber 16. The steam temperature is preferably between about 215 degrees Fahrenheit and about 275 degrees Fahrenheit. Valve means 40 are opened to permit the escape of steam/solvent vapors from the adsorbers through an adsorber battery outlet path 44.
The steam/solvent vapors are conducted by the path 44 to a vapor condensor means 48. The temperature of this mixture is preferably between about 200 degrees Fahrenheit and about 230 degrees Fahrenheit. The vapor condensor means 48 can be supplied with cooling means such as chilled water through the chilled water supply 50. The chilled water preferably has a temperature between about 35 degrees Fahrenheit and about 55 degrees Fahrenheit. Chilled water enters the vapor condensor means 48 through a chilled water supply path 54. The chilled water leaves the vapor condensor means 48 through a chilled water return path 56 which conducts the chilled water to a chilled water return 60. The steam consumption typically ranges from about 0.05 and about 0.50 lb. steam per pound of regenerated carbon.
Condensed water and solvents form the bottoms of the vapor condensor means 48 and are routed through a vapor condensor liquid exit path 62. Non-condensibles leave the vapor condensor means 48 through a vapor condensor vapor exit path 64. The temperature of the non-condensibles and liquids leaving the vapor condensor 48 preferably ranges between about 110 degrees Fahrenheit and about 130 degrees Fahrenheit. Seal bottle means 68 can be provided and connected to the vapor condensor liquid exit path 62 and the vapor condensor vapor exit path 64 to monitor the liquid level in the vapor condensor means 48.
Non-condensibles leaving the seal bottle means 68 are passed through a seal bottle vapor exit path 72 and can be returned to the SLA intake path 12 but preferably are directed to a vent condensor means 76. The vent condensor means 76 receives cooling means such as chilled water from the chilled water supply 50 through a vent condensor chilled water supply path 80. Chilled water leaves the vent condensor means 76 through a vent condensor chilled water return path 84. Condensibles leave the vent condensor means 76 through a vent condensor liquid exit path 88 which can lead to vent condensor seal bottle means 90. Vapors leave the vent condensor means 76 through a vent condensor vapor exit path 92, which also can be connected to the vent condensor seal bottle means 90. Vapors and condensibles leaving the vent condensor means 76 will preferably have a temperature between about 60 degrees Fahrenheit and about 80 degrees Fahrenheit. Vapors leave the vent condensor seal bottle means 90 through a vent condensor seal bottle vapor exit path 96 which connects to a SLA return path 100. The SLA return path 100 returns the vapors to the SLA inlet path 12 so that these vapors can be passed again through the adsorption/regeneration system.
Condensibles leaving the vent condensor seal bottle means are conducted by a vent condensor seal bottle liquid exit path 104 to liquid separation means such as the decanter means 108. Liquids leaving the vapor condensor seal bottle means 68 are conducted by a vapor condensor seal bottle liquid exit path 110 to heat exchanger mean 114. The heat exchanger means 114 is adapted to cool the liquids received from the vapor condensor 48 to a temperature substantially equal to the temperature of the liquids received from the vent condensor 76, as the latter will generally be significantly cooler than the former. The heat exchanger means receives chilled water or the like from the chilled water supply 50 through a heat exchanger chilled water supply path 120. Chilled water is returned through a heat exchanger chilled water return path 122. Liquids leave the heat exchanger means 114 through a heat exchanger exit path 116 which joins the vent condensor seal bottle liquid exit path 104, and both streams of liquids are passed to the decanter means 108.
The decanter means 108 separates-the liquid into a heavy solvent layer and a water layer. In the case of chlorofluorocarbons and other halogenated hydrocarbons, the heavy solvent layer will form the bottom of the decanter means 108 and can exit through a solvent exit path 126 to a product quality control tank 130. The water layer will thus form at the top of the decanter means 108 and leaves the top of the decanter means 108 through a decanter water exit path 134. Non-condensibles leave the decanter means 108 through a decanter vapor exit path 136 which joins the SLA return path 100 to return these vapors to the SLA inlet path 12.
The concentrations in the different vapor and liquid phases will be determined, at the limit, by equilibrium conditions for the compounds that are present and operating parameters such as temperature and inlet concentrations. The equilibrium condition will be disrupted by the constant withdrawal of compounds from the process. A dynamic equilibrium may be attained, but must be calculated or determined empirically on a case by case basis.
The water layer leaving the decanter means 108 preferably is carried by the decanter water exit path 134 to scrubbing means such as the air stripper means 138. Air is supplied to the air stripper means 138 from an ambient air supply path 140 which receives the air from a source 141. The air stream preferably has a temperature between about 70 degrees Fahrenheit and about 150 degrees Fahrenheit. Air leaves the air stripper means 138 through an air exhaust path 142 which preferably joins the SLA intake path 12 for adsorption/regeneration. The treated water leaving the air stripper means 138 is conducted by an air stripper water outlet path 143 to a condensate storage tank 144. Water used in the process can be made up from a chilled water make up supply 148 which is supplied to the system through a chilled water make-up inlet path 150 connecting to the chilled water system preferably at or near the chilled water supply 50.
The adsorbers 16 can be selected from several suitable designs. The flow of SLA through the adsorbers is preferably directed downward through the adsorption beds. The charge of carbon in each adsorber can vary for the particular process parameters and equipment sizing. The working capacity of the carbon, defined as the unit weight of solvent adsorbed per one hundred unit weight of carbon is between about 1% and about 15%.
The inlet of the SLA to adsorbers connected in a series is generally to the adsorber in the series that has been in the adsorption cycle for the longest period of time. This adsorber receiving the inlet SLA will generally be the next adsorber in the series to undergo regeneration. Adsorbers returning to the series from the regeneration cycle will generally be last in the series from the SLA inlet. This principle can be practiced with any number of adsorbers in series, and variations are possible. The flow connections can be adapted to fit the purposes and equipment at hand. It is also possible to provide electronic control of the valves to automatically switch the position of the adsorbers in the adsorption cycle and the regeneration cycle when pre-determined conditions are met.
The use of series adsorbers is depicted schematically in FIGS. 2(a)-(c), wherein two adsorbers are shown connected in series in any point in the adsorption process. The series of adsorbers 191-193 receives SLA from the inlet source 10. In the first mode of operation shown in FIG. 2(a), the adsorber 191 receives the SLA through a branch SLA path 182. The SLA travels from the outlet of adsorber 191 through a path 184 to the inlet of adsorber 192. Treated air leaves adsorber 192 through an outlet path 186 which connects to the path 20 such that the treated air is released through the vent 22 (FIGS. 1-2).
Adsorber 193 undergoes regeneration and is shown removed from the adsorption series, which removal can be accomplished through the appropriate switching of valve means. Steam supplied from a source 194 is passed by a steam line 200 to the adsorber 193 The steam line 200 preferably opens into the adsorber 193 beneath the adsorption bed so that the flow of steam through the bed is upward. The steam and solvent vapors leave the adsorber 193 through an adsorber exit path 204. The adsorber exit path 204 connects to the adsorber battery outlet path 44 (FIG. 1), where the steam/solvent mixture is processed as described above to separate solvents. Condensibles leave the adsorber 193 through an adsorber condensate outlet path 209 which opens into a battery condensate collection tank 210.
In a second mode of operation (FIG. 2(b)), flow through the adsorbers has been rerouted through alternate flow paths by the appropriate switching of valves. Adsorber 192 receives SLA from the SLA source 10 through a second branch SLA path 212, and is now the first adsorber in the adsorption series. SLA travels out of adsorber 192 through a path 214 to the third adsorber 193, after which it is exhausted through a path 218, which connects to the path 20 and the vent 22.
Adsorber 191 undergoes regeneration in the second mode of operation. Steam is supplied from the source 194 to adsorber 191 through a branch steam path 224. Steam and solvent vapors exit through an adsorber outlet path 228 to the adsorber battery outlet path 44. Condensibles leave the adsorber 191 through a second adsorber condensate outlet path 232 which opens into the battery condensate collection tank 210.
In the third mode of operation adsorber 193 receives SL from the SLA source 10 through a third branch SLA path 236. The SLA leaves the adsorber 193 through an outlet path 238 which connects to the inlet of adsorber 191. Treated air leaves adsorber 191 through an outlet path 240 which connects to the path 20 and the vent 22 Adsorber 192 undergoes regeneration and receives steam from the steam source 194 through a branch path 248. Steam leaves the adsorber 192 through an adsorber outlet path 250 and is passed to the adsorber battery outlet 44. Condensibles leave the adsorber 192 through an adsorber condensate exit path 254 which joins the battery condensate collection tank 210.
It is preferable to pre-condition the SLA prior to adsorption. A suitable pre-conditioning unit is shown in FIG. 3. The pre-conditioning components can be assembled in a single housing 270 which can receive the SLA from the SLA source 10 through an input path 274. A guard bed 278 is positioned in the flow path to remove extraneous contaminants such as oils, particulates, and the like that might prematurely plug the main beds in the adsorbers. The guard bed thereby prolongs the life of the adsorber beds. The guard bed preferably consists of a small charge of carbon, which can range from 5% to 15% of the weight of carbon in the adsorption beds of the adsorbers 191-193. The small size of the guard bed provides easy and inexpensive removal and replacement of the carbon when it becomes contaminated. The adsorption beds, which contain much larger charges of carbon, are expensive to replace and usually bed lives of several months to a few years are desired. The guard bed helps to insure that such a life for the adsorption beds will be attained.
A particulate filter 282 can be provided downstream from the guard bed. The particulate filter 282 removes minute solids from the air stream which have passed the guard bed 278. The particulate filter 282 can be selected from a number of filter means suitable for this purpose.
It is also preferable to adjust the temperature and relative humidity of the incoming SLA for maximum process efficiency. The temperature of the SLA entering the adsorber battery is preferably between 60 degrees Fahrenheit and about 80 degrees Fahrenheit. The relative humidity is preferably between about 15% and about 60%. Cooling of the SLA stream can be accomplished in heat exchanger means. The cooling heat exchanger means 284 can be selected from a number of heat exchange devices suitable for this purpose. The cooling heat exchanger 284 can be a coil exchanger supplied with a cooling fluid such as chilled water. The chilled water is received through a chilled water inlet path 288 and exits through a chilled water exit path 290. The SLA can be warmed through a heating heat exchanger 292 which can be selected from a number of suitable designs. The heating heat exchanger 292 can be a coil exchanger which receives steam through a steam inlet path 296. Steam exits the exchanger through a steam exit path 300.
Conventional blower means 310 can be provided to raise the pressure of the SLA inlet stream to a desired level for maximum adsorption efficiency. The blower means 310 can be selected from a number of blower means suitable for this purpose. The blower means 310 receives the SLA from a blower inlet path 312 and exits the blower means 310 through a blower exit path 315. The SLA can be passed from the blower exit path 315 directly to the adsorption stage 16 of the process.
Cooling means such as a stream of cooling air is preferably applied to the adsorption beds immediately after regeneration to cool the beds prior to returning them to the adsorption cycle. Cooler beds have been found to result in more efficient adsorption. Air is a preferable cooling fluid because of its ready availability. Ambient air can be drawn from an inlet 320 into an air inlet path 324 which directs the air to a filter means 328 adapted to filter particulates from the air. The filter 328 can be selected from a number of filters suitable for this purpose. Cooling air leaves the filter 328 and is directed by a cooling blower inlet path 330 to a cooling blower means 336. The cooling blower means 336 ensures a proper flow through the adsorption bed during the cooling cycle. The cooling blower means 336 can be selected from a number of blower devices suitable for this purpose. Air leaves the cooling blower means 336 through a cooling blower exit path 340.
The temperature of the cooling air is preferably between about 32 degrees Fahrenheit and about 150 degrees Fahrenheit. Heat exchange means such as the steam coil heat exchanger 344 can be provided to adjust the temperature of the cooling air as desired. The steam coil heat exchanger 344 receives steam through a steam inlet path 346 and exhausts the steam through a steam exit path 350. Air leaves the heat exchange means cooling air to the adsorption beds for the cooling cycle.
EXAMPLE
The following example is intended to demonstrate the operation of the process. Actual process variables including temperature, flow rates, and equipment design and sizing may vary widely depending on the type and loading of the solvents, the inlet conditions including temperature, relative humidity and flow rate, as well as the removal efficiency that is desired.
A solvent laden airstream flowing at a rate of 3,000 SCFM has a temperature of 70 degrees Fahrenheit and a relative humidity of 25%. The solvent to be removed is chlorofluorocarbon 113 at a concentration of 5,000 ppm, by volume, or a mass flow rate of 450 pounds per hour. The targeted emission level in the treated air is 50 ppm, by volume, or a removal efficiency of approximately 99%.
Three adsorbers are incorporated in the example design. Two adsorbers are adsorbing in series at any time, while a third undergoes regeneration and stand-by. The adsorption temperature is 70 degrees Fahrenheit, the carbon load per adsorber is 4,500 pounds, and the design working capacity of the carbon is 10%. Steam consumption for regeneration is approximately 0.25 pounds steam per pound of carbon. A guard bed is provided and comprises 5% of the carbon loading in the main adsorber, or 225 pounds.
This invention can be embodied in other forms without departing from the spirit or essential attributes thereof and accordingly, references should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention. | A process for removing halogenated hydrocarbons and other solvents from a solvent laden air (SLA) stream, includes the step of passing the SLA from an SLA intake through at least three adsorbers each containing an activated carbon bed. At least one adsorber undergoes regeneration while at least two other adsorbers operate in series in the adsorption mode. Regeneration is accomplished by passing a regenerating fluid such as steam through the bed. The steam and solvent vapor is condensed to form a liquid having at least one solvent rich fraction and at least one solvent poor fraction. This condensation product undergoes one or more separation steps to remove the solvent rich fractions from the solvent poor fractions. Non-condensibles are returned to the SLA intake. The SLA is pre-conditioned prior to the SLA inlet to remove extraneous contaminants and to control inlet conditions of temperature, relative humidity and flow rate. Removal efficiencies of 99 percent and above are attainable by the process. | 1 |
CROSS REFERENCES TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to packaging material for flowable food containers. Specifically, the present invention relates to a laminate composed of at least one layer of a corrugated packaging material for a container for flowable materials.
2. Description of the Related Art
Containers for flowable food products are available in various forms. One form is the commonly recognizable gabletop carton such as the TETRA REX® carton available from Tetra Pak, Inc. of Chicago, Ill. Another type of container is the ubiquitous TETRA BRIK® parallelepiped container also available from Tetra Pak, Inc. of Chicago, Ill. The gabletop carton includes four side panels which are finished, at the top, with a peaked, gable-like configuration while the parallelepiped container is formed from a web of material and has four sides and a substantially flat top and bottom. Such containers are used for packaging and storing liquid foods such as milk, juice and the like, as well as other, consumer liquid products such as laundry detergent. Such containers are also used for storing dried, powdered and granulated good, such as dried soups. Such containers are also known for use in storing medicinal goods such as powdered or granulated Epsom salts.
Traditionally, such gabletop cartons are formed from "blanks" which are formed or erected and transported into a filling apparatus in which the carton is filled and the top or gable portion folded and sealed. The blanks are shipped and stored unformed or flat. The cartons are generally erected within the filling machine. As mentioned above, parallelepiped containers are fabricated on a vertical form, fill and seal packaging machine from a web of material.
In a common arrangement for liquid packaging and storage, the packaging material is formed from a laminated structure. One known laminate includes a fiberboard substrate having a layer or a coating of a polymeric material, such as low density polyethylene (LDPE) on both sides of the substrate. The "sides" of the substrate are the inside and outside surfaces of the container is completely formed.
The polymeric layers provide a measure of liquid impermeability to the material, thus providing a substantially "leak resistant" container, with the inner polymeric layer preventing leakage from the container outward, and the outer polymeric layer retarding moisture or humidity transfer from the environs inward. The laminated structure also reduces wicking of the material, which is absorption of liquid by the container material, and subsequent mass transfer, of the liquid from the site of absorption.
The laminate may also include a barrier layer adjacent to the substrate, between the substrate and the inner polymeric layer. The barrier layer enhances gas impermeability of the carton which facilitates retaining the container contents fresh. The barrier layer can be positioned directly on the substrate. Alternately, and preferably, the laminate can include a polymeric layer between the barrier layer and the substrate as well as a polymeric layer over the barrier. In this configuration, the polymeric layer that is disposed between the barrier and the substrate can serve to adhere the barrier and substrate to one another. Such barrier layers are used, typically, in cartons for storing fruit juice and the like.
A major cost in the manufacture of such containers is the cost of the paper materials, which correlates to paper grammage for each container. Paper products are often measured in "grammage", which is the weight of the board in grams per square meter, (gms/m 2 ). As such, increased "grammage" of materials generally correlates to increased cost. Any reduction in paper grammage generally brings about a savings in the cost of the container. However, relatively lighter weight materials, i.e., lower grammage materials, generally have less strength than materials having a higher grammage. As such, a balance must be made between cost reduction and strength.
Accordingly, there continues to be a need for a lighter weight material for the manufacture of paperboard and paperboard-like Paper products are often measured in "grammage", which is the weight of the board in grams per square meter (gms/m 2 ). As such, increased "grammage" of materials generally correlates to increased cost. Such a material and carton configuration provides strength and durability in a reduced cost package for packaging and storing solid, viscous and liquid goods.
BRIEF SUMMARY OF THE INVENTION
One aspect of the present invention is a laminated packaging material for a flowable food container. The laminated packaging material has a first layer, a second layer and a fluted medium therebetween. The first and second layers are composed of a fiberboard material. The fluted medium is juxtaposed between the inner surfaces of the first and second layers. The fluted medium has a flute density of 200 to 450 flutes per linear foot.
Another aspect of the present invention is a laminated packaging material for a flowable food container having a first and second layers with a third sinusoidal layer therebetween. The first and second layers are composed of a fiberboard material with a polymeric material coating thereon. The third layer is juxtaposed between the inner surfaces of the first and second layers. The sinusoidal cross-section of the third layer forms a plurality of compartments extending the length of the laminated packaging material. Each of the plurality of compartments is defined by a the third layer and one of the first and second layers.
It is a primary object of the present invention to provide a laminated packaging material having a fluted medium juxtaposed between two fiberboard layers.
It is an additional object of the present invention to provide a laminated packaging material which provides substantial material savings.
Having briefly described this invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Several features of the present invention are further described in connection with the accompanying drawings in which:
There is illustrated in FIG. 1A a perspective view of a corrugated gabletop carton embodying the principles of the present invention, the carton being shown with an integral flap-type pour spout, and being shown for illustrative purposes with flute column lines thereon;
There is illustrated in FIG. 1B a perspective view of a corrugated parallelepiped container embodying the principles of the present invention, the container being shown for illustrative purposes with flute column lines thereon;
FIG. 2A is a cross-sectional view of the preferred embodiment of the corrugated packaging material of the present invention;
FIG. 2B is a cross-sectional view of an alternative embodiment of the corrugated packaging material of the present invention;
FIG. 3A is a view of an unassembled or unerected carton, commonly referred to as a carton blank; and
FIG. 3B is a view of a section of a web of material from which the container 15 of FIG. 1B is fabricated on a form, fill and seal packaging machine.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures and in particular to FIG. 1A, there is shown a gabletop carton 10 formed of a corrugated material 12, 12'. The carton 10 defines a product storage region 11 and is adapted to directly store liquid products, such as milk and juice, viscous products, such as mayonnaise, and solid, e.g., granulated or powdered products. The carton 10 is configured to store these products without an intervening liner, such as a flexible polymeric bag disposed between the product and the carton. The carton 10 is formed from a material 12, 12' that is first prepared into a form commonly referred to as a carton "blank", illustrated at 14 in FIG. 3, to facilitate erecting the carton 10. The carton 10 shown in FIG. 1 includes a pour spout 16 formed from a portion of the carton material 12, 12'. The pour spout 16 folds back, inward of the carton 10 to form a reclosure for the carton 10.
The carton blank 14 is formed from a paperboard material 12, 12'. In known cartons formed of a typical solid wall construction, the material weight or grammage will vary depending upon the size and strength requirements of the carton, the weight and state (e.g., liquid or solid) of the contained product and the intended end use of the carton. In a known one-liter carton, the paperboard grammage is about 280 to about 300 gms/m 2 .
In FIG. 1B, a parallelepiped container 15 is shown. As mentioned previously, the container 15 is formed on a vertical form, fill and seal machine from a web of material. The web is sealed longitudinally to form a longitudinal seal 17, then sealed transversally to create a transverse seal 19. The container 15 is then folded and the top edges 21 are sealed to the sides of the container 15. A variation of this container 15 is the TETRA PRISMA™ package which is also available from Tetra Pak. Inc. of Chicago, Ill. A TETRA PRISMA™ package is disclosed in co-pending U.S. patent application Ser. No. 08/739,723 filed on Oct. 23, 1996.
Yet another type of container which may incorporate the novel packaging material is a TETRA TOP® container also available from Tetra Pak, Inc. of Chicago, Ill.
The carton 10 illustrated in FIG. 1A and the parallelepiped container 15 are both manufactured from the novel corrugated packaging material 12, 12' of the present invention, with cross-sections of exemplary materials 12, 12' shown in FIGS. 2A and 2B. Referring to FIG. 2A, the material 12 includes an inner facing sheet 18, an outer facing sheet 20 and a fluted medium 22 positioned between the inner and outer facing sheets 18, 20. The fluted medium 22 contacts and is fixed between the inner and outer facing sheets 18, 20. For purposes of the present discussion, the inner facing sheet 18 is the portion of the material 12, 12' that is inward of the carton 10 or the container 15, e.g., the inner surface 24 of the carton 10 that is in contact with the contained material, and the outer facing sheet 20 is that portion of the material 12, 12' that is outward of the carton 10, e.g., the outer surface 26 of the carton 10, that is handled by a user.
The inner and outer facing sheets 18, 20 can be formed from common paperboard material that have applied thereto a liquid resistant material such as the polymeric LDPE layers 28, 30 shown in FIG. 2A. The fluted medium 22 is typically formed from paperboard material that may have a liquid resistant material applied to one or both sides thereof, or may be used untreated.
Alternately, as shown in FIG. 2B, the inner and outer facing sheets 18, 20 can have polymeric layers 130, 132, 134, 136 disposed on each side of each facing sheet 18, 20 to serve as an adhesive to adhere the materials to one another. The polymeric layers 130, 132 and 134, 136 further reduce moisture transfer. As previously discussed, I a construction that includes a gas impermeable barrier 138 such as foil, the foil 138 can be positioned on the polymeric layer 130, and an additional polymeric layer 128 can be provided over the foil 138.
When observed vertically, the flutes f define columns 32 that traverse the material 12, 12' in a direction perpendicular to the wave-like form shown in FIG. 2. That is, the columns 32 are oriented into and out of the figure sheet of FIG. 2. This orientation also increases the grip stiffness. While the present discussion is directed to, and makes reference to the material 12 illustrated in FIG. 2A, it is to be understood that the present discussion applied equally well to the material 12' illustrated in FIG. 2B, as well as other corrugated material configurations.
When observed as a cross-section of the material traversing a plurality of columns 32, as seen in FIGS. 2A and 2B, the flutes f have an arch-like appearance. The arch is a basic structural shape that is capable of supporting substantial weight loads and is recognized as a structurally acceptable manner in which to span a given space. Those skilled in the art will also recognize that corrugated cartons can be formed having a plurality of walls, i.e., two or more corrugated media (not shown) having a facing sheet or liner board interposed between the corrugated media and facing sheets on the inner and outer surfaces thereof. It will be apparent from the drawings that the spaces s between the flutes f and between the flutes f and the facing sheets 18, 20 are open to the environs. It will also be recognized by those skilled in the art that the edges (from which the flutes f can be seen) can be sealed to seal the spaces s and prevent moisture ingress and wicking.
Referring to FIG. 2A, the material 12 can include one or more polymeric layers 28, 30, such as the aforementioned LDPE, to provide further liquid resistance, and a barrier layer 34 to provide gas impermeability. In a preferred arrangement, the barrier 34 is a metal foil, such as aluminum foil. The barrier layer 34 reduces the passage of gas, such as oxygen, through the carton 10, and thus enhances the ability of the carton 10 to maintain the contents fresh. Typically, as provided previously, and as illustrated in FIG. 2B, the barrier layer 138 is disposed on the facing sheet 18 with a polymeric layer 130 between the facing sheet 18 and the barrier 138. An additional polymeric layer 128 is provided over the barrier 138 as an innermost laminate material.
Referring now to FIG. 3A, there is shown a carton blank 14, in unerected form. The blank 14 includes five vertical panels 14a-e defined by four vertical score lines or creases 36a-d. Four of the vertical panels 14a-d define the side walls 38a-d of the carton 10. The fifth vertical panel 14e provides a tab for sealing the carton blank walls 38a and 38d adjacent to one another when the carton 10 is erected or formed
The blank 14 further includes three horizontal score lines or creases 40a-c. The lower horizontal line 40a, along with the portions of the vertical side wall creases 36a-d below the lower horizontal line 40a, define the bottom wall portion 42 of the carton 10. The two upper horizontal lines 40b-c, along with the portions of the vertical side wall creases 36a-d above the horizontal line 40b, define the top portion 44 of the carton 10 including the gable 46. The top portion 44 of the blank 14 also includes a plurality of angled gable creases or score hues 48a-f that define the gable 46 and pour spout 16. The gable includes inner and outer gable walls, 46a and 46b, respectively. Upper and lower fins 50, 52 facilitate sealing the carton blank walls 14a-d to one another when the carton 10 is erected.
A section of the web 39 of packaging material from which the container 15 is formed is shown in FIG. 3B. The section of the web 39 has a plurality of crease lines 41 which are manipulated to create the container 15 on a vertical form, fill and seal packaging machine.
A preferred embodiment of the carton 10 and the container 15 includes the carton material 12, 12' oriented such that the columns 32 traverse across the side walls 38a-d. That is, referring to FIGS. 1A and 1B, the columns 32 traverse in the direction shown by the lines indicated at 54. In this configuration, the columns 32 will intersect and will be redirected by the vertical side wall creases 36. As discussed previously, this orientation of the material 12, 12' increases the grip stiffness.
Standards were, at one time, promulgated for fluted material in which material was identified by an alpha character followed by the word "flute". For example, "A-flute" represented a material having 33± flutes per linear foot and an approximate height of 3/16 inch exclusive of the facing thickness. "E-flute" represented a material having 90±4 flutes per linear foot and an approximate height of 3/64 inch exclusive of the facing thickness. Although various flute f sizes can be used for the present invention, it is contemplated that a preferred material 12, 12' has a density of about 200 to about 450 flutes f per linear foot and most preferably a flute density of about 250 flutes per linear foot. Preferably, the material 12, 12' has an approximate flute f height or profile h of about 8 mils to about 50 mils, and most preferably about 8 mils to about 40 mils, exclusive of the facing sheet 18, 20 thickness.
It will be understood that the flute f density and height profile can vary depending upon the pressure applied to the material 12, 12' during the converting process, as the material is introduced to pressure or nip rollers that facilitate application of the facing sheets to the fluted medium.
Advantageously, the use of a material 12, 12' having a relatively high flute density, (i.e., closely or tightly positioned flutes) provides substantially flat inner and outer facing sheet outer surfaces 56, 58. That is, the outwardly facing surfaces 56, 58 of the inner and outer facing sheets 18, 20 define substantially flat planes that are readily printable with, for example, indicia such as graphics including logos and designs, information regarding the contents of the carton 10 or the container 15, and the manufacturer or packager The tightly positioned flutes f also provide a carton 10 or container 15 that has a smooth appearance rather than the ridged or rippled appearance generally associated with corrugated materials.
The novel use of a corrugated material 12, 12' for in a carton 10 or container 15, for example, for storing viscous materials and liquids such as juices, provides a number of advantages over the use of solid single or multi-layered paperboard materials. First, the weight of the can be reduced by using a corrugated material 12, 12'. Commensurate with a reduction in weight, generally, is a reduction in cost. Moreover, there is no loss in structural strength of integrity of the carton 10 or container 15 formed from corrugated material 12, 12'. Rather, it is contemplated that corrugated cartons 10 or containers 15 of the present invention can be configured to reduce weight over like solid wall cartons, while increasing the strength. Thus, when considering the carton 10 or container 15 on the basis of strength per unit weight (e.g., strength per grammage), the present corrugated cartons 10 or containers 15 provide a significant advantage over the known solid single or multi-layered paperboard cartons.
The reduction in raw material requirements, e.g., material weight, associated with the manufacture of the carton 10 or container 15 is commonly referred to as source reduction. Source reduction is the prevention of waste at its source by using the minimum quantity of materials necessary to achieve a given function. Use of corrugated materials in the manufacture of gabletop cartons, in accordance with the principles of the present invention furthers source reduction objectives. Thus, source reduction has environmental benefits as well as optimizing resources and minimizing costs.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims: | A laminated packaging material for fabrication into a container for a flowable food product is disclosed herein. The laminated packaging material has a fluted medium between a first layer and second layer. The fluted medium may have a flute density of 200 to 450 flutes per linear foot. The fluted medium may also have a flute height profile of 8 mils to 50 mils. The laminated packaging material may be fabricated into a gabletop carton or a parallelepiped container such as the TETRA BRIK® container. The laminated packaging material may have a barrier layer such as aluminum or another gas impermeable composition. The laminated packaging material provides substantial material savings due to the fluted medium. | 8 |
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a printer, and more specifically, the present invention discloses a printer that is capable of setting a calibration position within a range in which a print head is able to print a document.
2. Description of the Prior Art
Please refer to FIG. 1 . FIG. 1 is a perspective view of a printer 10 disclosed in U.S. Pat. No. 5,861,726. The printer 10 comprises a housing 12 , a carriage 14 installed inside the housing 12 that moves in right and left directions on a horizontal track 16 , an ink container 18 installed on the carriage 14 , a print head 20 set on the ink container 18 , and a step motor 30 for driving the carriage 14 . The printer 10 further comprises a light source 22 , and a light sensor 24 installed outside a printing range of the printer 10 . The carriage 14 further comprises a shield 26 for blocking light transmitted from the light source 22 to the light sensor 24 .
The step motor 30 drives the carriage 14 to move left and right along the horizontal track 16 , so that the print head 20 is able to print the document. Before the printer 10 starts to print the document, the printer 10 calibrates a position of the carriage 14 to a zeroed position, i.e. the position that the light source 22 and the light sensor 24 is at, outside of the printing range. The position of the carriage 14 is calibrated by using the step motor 30 to drive the carriage 14 to move until the shield 26 on the carriage 14 blocks the light transmitted from the light source 22 to the light sensor 24 . When starting printing of the document, the step motor 30 drives the carriage 14 to a printing start point, so as to enter the printing range, then prints the document until printing is finished, or the next calibration time, at which time the position of the carriage 14 is zeroed again.
In the prior art printing method, the printer 10 is unable to detect immediately if the position of the print head 20 is not accurate, so the print head 20 continues printing on a wrong position, until the whole document is printed, or the next calibration. This wastes time and ink.
SUMMARY OF INVENTION
It is therefore a primary objective of the claimed invention to provide a printer that is capable of setting the calibration position inside the printing range. While not consuming excess time, the printer is able to detect the position of the print head in the printing process, so as to check whether the position of the print head is correct or not. If the error of the print head position is too large, then the printer is able to stop printing and calibrate the position of the carriage instantly, not wasting printing time and ink.
The claimed invention, briefly summarized, discloses a printer including a position detecting mechanism for detecting and calibrating a position of a carriage on a horizontal track, and a print head installed on the carriage for printing a document. The position detecting mechanism has a first portion installed at a calibration position of the horizontal track, and a second portion installed on the carriage. The calibration position is positioned within a document printing range of the print head, so that the second portion is capable of passing by the first portion during a printing process.
It is an advantage of the claimed invention that the printer has a position detecting mechanism installed within the printing range of the print head, so that the position of the carriage is detected and calibrated in the printing process. If an error of the print head position exceeds a predetermined range, but is within an acceptable range, the printer can calibrate the position of the carriage after printing the document. In contrast, if the position of the print head has a serious misalignment, then the printer may stop printing the document and calibrate the position of the carriage instantly, to avoid wasting printing time and ink.
These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment, which is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a printer according to the prior art.
FIG. 2 is a perspective view of a present invention printer.
FIG. 3 is a diagram of a relation between an output signal of a light sensor and a position of a light source and the light sensor on a carriage.
FIG. 4 is a perspective view of a second embodiment of the present invention printer.
FIG. 5 is a perspective view of a third embodiment of the present invention printer.
FIG. 6 is another perspective view of the third embodiment of the present invention printer.
DETAILED DESCRIPTION
Please refer to FIG. 2 . FIG. 2 is a perspective view of a printer 50 according to the present invention. The printer 50 comprises a housing 52 , a carriage 54 installed within the housing 52 that can move back and forth in left and right directions on a horizontal track 56 , an ink container 58 installed on the carriage 54 , a print head 60 communicated with the ink container 58 for ejecting the ink onto a document while the carriage 54 is moving in left and right directions. The printer 50 further comprises a shield 94 installed on the base of the housing 52 within the printing range in which the print head 60 can print information onto the paper. The shield 94 is used to detect and calibrate the position of the carriage 54 . The printer 50 also has control circuitry 80 for controllings operations of the printer 50 , and a step motor 82 for driving the carriage 54 . The control circuitry 80 comprises a counter 72 , which counts rotational steps of the step motor 82 to record the counted position of a light source 90 and a light sensor 92 disposed on the carriage 54 .
The shield 94 comprises a first edge 96 and a second edge 98 . The control circuitry 80 records positions of the first edge 96 and the second edge 98 of the shield 94 corresponding to the horizontal track 56 . The position of the first edge 96 of the shield 94 is corresponding to a first calibration position of the horizontal track 56 . The position of the second edge 98 of the shield 94 is corresponding to a second calibration position of the horizontal track 56 .
The printing process operated among those components shown in FIG. 2 is further explained below. During movement of the carriage 54 from the end point 97 toward the end point 99 of the horizontal track 56 , when the light source 90 and the light sensor 92 move to the first calibration position (first edge 96 ), the shield 94 starts to block the light transmitted from the light source 90 to the light sensor 92 . Then, the control circuitry 80 compares (a) the first counted position of the light source 90 and the light sensor 92 along the horizontal track 56 (the rotational steps of step motor 82 counted by the counter 72 ), with (b) the first calibration position (the predetermined first rotational step count recorded in the control circuitry 80 ), to obtain a first difference between the two positions.
When the light source 90 and the light sensor 92 on the carriage 54 move to the second calibration position (second edge 98 ), the light sensor 92 starts to receive the light transmitted from the light source 90 again. Then, the control circuitry 80 compares (a) the second counted position of the light source 90 and the light sensor 92 along the horizontal track 56 (the rotational steps of step motor 82 counted by the counter 72 ), with (b) the second calibration position (the predetermined second rotational step count recorded in the control circuitry 80 ), to obtain a second difference between the two positions.
If (a) the first difference between the first calibration position and the first counted position of the light source 90 and the light sensor 92 , or (b) the second difference between the second calibration position and the second counted position of the light source 90 and the light sensor 92 is less than a first predetermined range, then the control circuitry 80 does not need to calibrate the position of the carriage 54 . This is because the difference is within a permissible error tolerance.
If (a) the first difference between the first calibration position and the first counted position of the light source 90 and the light sensor 92 , or (b) the second difference between the second calibration position and the second counted position of the light source 90 and the light sensor 92 is larger than the first predetermined range but less than the second predetermined range, then the control circuitry 80 calibrates the position of the carriage 54 after the on-going document printing process is completed. The control circuitry 80 need not stop printing and calibrate the position of the carriage 54 immediately. In this situation, there does exist certain minor position error of the carriage 54 , but the influence is limited.
Otherwise, if a) the first difference between the first calibration position and the first counted position of the light source 90 and the light sensor 92 , or (b) the second difference between the second calibration position and the second counted position of the light source 90 and the light sensor 92 is greater than the second predetermined range, then the control circuitry 80 will instantly stop printing the document and calibrate the position of the carriage 54 . In this situation, there does exist serious position error of the carriage 54 to affect the print out quality.
Please refer to FIG. 3 . FIG. 3 is a diagram of a relation between (a) the output signal of the light sensor 92 and (b) the light source 90 and the light sensor 92 moving along the horizontal track 56 . In FIG. 3, F represents the first calibration position corresponding to the first rotational step count recorded in the control circuitry 80 . The first predetermined range corresponding to a smaller tolerance around the first calibration position is defined by the area between F0− and F0+. The second predetermined range corresponding to a larger tolerance around the first calibration position is defined by the area between F1− and F1+.
In theory, as shown in FIG. 3, when the light source 90 and light sensor 92 arrive at the position F, then the shield 94 starts to block the light transmitted from the light source 90 to the light sensor 92 . Therefore, when the output signal of the light sensor 92 changes from a high voltage to a low voltage, the counted position (the rotational steps counted by the counter 72 ) should be same as the first calibration position F (the first rotational step count recorded in the control circuitry 80 ). However, in practice, when the transition of the output signal of the light sensor 92 occurs, the rotational steps counted by the counter 72 does not always equal to the first rotational step count recorded in the control circuitry 80 which represents the first calibration position F.
If the output signal of the light sensor 92 changes when the light source 90 and the light sensor 92 arrive at the range between F0− and F0+, then the control circuitry 80 does not need to calibrate the position of the carriage 54 because the position of the carriage 54 only has a very minor deviation. If the output signal of the light sensor 92 changes when the light source 90 and the light sensor 92 arrive at the range between F1− and F0−, or at the range between F0+ and F1+, then the control circuitry 80 must calibrate the position of the carriage 54 after the on-going document printing process is completed because the deviation is still tolerable for the on-going document. If the output signal of the light sensor 92 changes while the light source 90 and the light sensor 92 have not reached the position F1−, or when the light source 90 and the light sensor 92 have passed the position F1+, then the control circuitry 80 must instantly stop printing the document and calibrate the position of the carriage 54 . This is because the position of the carriage 54 has a severe deviation.
A position detection method when the light source 90 and the light sensor 92 on the carriage 54 arrive the second calibration position is similar to the position detection method when the light source 90 and the light sensor 92 on the carriage 54 arrive the first calibration position.
In the present invention, the printer 50 detects the difference between the first and second counted positions of the light source 90 and the light sensor 92 and the first and second calibration positions at the horizontal track 56 , recorded by the control circuitry 80 . The printer 50 detects the above difference once whenever the light source 90 and the light sensor 92 pass through the first or second calibration position once in either process: (a) the carriage 54 moving from the end point 97 towards the end point 99 , or (b) the carriage 54 moving from the end point 99 towards the end point 97 .
Moreover, the printer 50 is also capable of detecting the difference between the position of the light source 90 and the light sensor 92 , corresponding to the horizontal track 56 , and the position which the first or second calibration position at the horizontal track 56 , recorded by the control circuitry 80 . This difference will be measured when the light source 90 and the light sensor 92 pass through the first or second calibration position.
Please refer to FIG. 4 . FIG. 4 is a perspective view of a second embodiment of a present invention printer 100 . The difference between the printer 100 of the second embodiment and the printer 50 of the first embodiment is the shield 94 of the printer 100 is installed on the carriage 54 , and the light source 90 and the light sensor 92 of the printer 100 are installed on the housing 52 within a range in which the print head 60 is capable of printing the document. The position of the light source 90 and the light sensor 92 of printer 100 corresponds to the calibration position of the horizontal track 56 , for detecting the position of the carriage 54 .
In the process of the print head 60 printing the document shown in FIG. 4, the first edge 96 of the shield 94 moves towards the end point 99 of the horizontal track 56 to a position in which the shield 94 starts to block the light transmitted from the light source 90 to the light sensor 92 . When this happens, the control circuitry 80 compares (a) the first counted position of the first edge 96 of the shield 94 represented by the rotational steps counted by the counter 72 , with (b) the predetermined calibration position recorded in the control circuitry 80 , and obtains a difference between the two positions.
Later, the shield 94 further moves and makes the second edge 98 of the shield 94 move to a position in which the light sensor 92 starts to receive the light transmitted from the light source 90 again. When this occurs, the control circuitry 80 compares (a) the second counted position of the second edge 98 of the shield 94 represented by the rotational steps counted by the counter 72 , with (b) the predetermined calibration position recorded in the control circuitry 80 , and obtains a difference between the two positions.
If the difference between the counted position of the first edge 96 or the second edge 98 of the shield 94 and the calibration position at the horizontal track 56 exceeds a first predetermined range but within a second predetermined range, then the control circuitry 80 calibrates the position of the carriage 54 after the on-going printing process is completed.
If the difference between the counted position of the first edge 96 or the second edge 98 of the shield 94 and the calibration position at the horizontal track 56 exceeds the second predetermined range, then the control circuitry 80 instantly stops printing the document and calibrates the position of the carriage 54 immediately.
Similarly, the printer 100 detects the above difference once whenever the first edge 96 or the second edge 98 passes through the calibration position once in either process: (a) the carriage 54 moving from the end point 97 towards the end point 99 , or (b) the carriage 54 moving from the end point 99 towards the end point 97 .
Please refer to FIG. 5 and FIG. 6 . FIG. 5 and FIG. 6 are perspective views of a third embodiment of a present invention printer 110 . The difference between the printer 110 and the printer 50 is the printer 110 uses a DC motor 114 to drive the carriage 54 . The printer 110 further comprises an optics ruler 112 installed on the housing 52 . The carriage 54 further has a light source 108 installed for transmitting the light towards the optics ruler 112 , and a light sensor 106 for detecting the light transmitted from the light source 108 and through the optics ruler 112 and generating the corresponding position signal. The counter 72 is used, according to the position signal generated by the light sensor 106 , to indicate the position of the light source 90 and the light sensor 92 , corresponding to the horizontal track 56 .
Similarly, the printer 110 is also able to use the DC motor 114 to drive the carriage 54 . The printer 110 is able to use the optics ruler 112 , light source 108 , and the light sensor 106 to generate the position signal. Based on the position signal generated from the optical ruler 112 , the counter 72 is able to record the first counted position of the first edge 96 or the second counted position of the second edge 98 , corresponding to the horizontal track 56 .
In contrast to the prior art, the present invention printer is able to stop printing the document and calibrate the position of the carriage instantly when the position of the print head has a serious error, not wasting printing time and ink. If the error of the print head position exceeds a predetermined range but is still tolerable, the printer can calibrate the position of the carriage after printing the document. This avoids wasting the printing document, and ensures the printing quality of the next document.
Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only be the metes and bounds of the appended claims. | A printer includes a position detecting mechanism for detecting and calibrating a position of a carriage on a track, and a print head installed on the carriage for printing a document. The position detecting mechanism has a first portion installed at a calibration position neighboring the track, and a second portion installed on the carriage. The calibration position is positioned within a document printing range of the print head so that the second portion is capable of passing by the first portion during a printing process. | 1 |
[0001] This application claims the benefit of Korean Patent Application No. 2004-62382, filed on Aug. 9, 2004, which is hereby incorporated by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a liquid crystal display (LCD) device, and more particularly, to an LCD device and a method of fabricating the LCD device.
[0004] 2. Description of the Related Art
[0005] Presently, LCD devices are being developed as the next generation of display devices because of their light weight, thin profile, and low power consumption. In general, an LCD device is a non-emissive display device that displays images using a refractive index difference utilizing optical anisotropy properties of a liquid crystal material that is interposed between an array (TFT) substrate and a color filter substrate. Among the various type of LCD devices commonly used, active matrix LCD (AM-LCD) devices have been developed because of their high resolution and superiority in displaying moving images. The AM-LCD device includes a thin film transistor (TFT) in each pixel region as a switching device, a pixel electrode in each pixel region, and a second electrode used for a common electrode.
[0006] FIG. 1 is a schematic cross sectional view of an LCD device according to the related art. In FIG. 1 , an LCD panel 1 includes upper and lower substrates 5 and 22 arranged to face each other with a liquid crystal layer 14 interposed therebetween. A color filter layer 7 and a common electrode 18 overlie an inner surface of the upper substrate 5 , in which the common electrode 18 functions as an electrode for applying an electric field to the liquid crystal layer 14 . The color filter layer 7 includes red, green and blue color filters 7 a , 7 b and 7 c for passing only a specific wavelength of light, and a black matrix 6 that is disposed at the boundary between the red, green and blue color filters 7 a , 7 b and 7 c and shields light from a region in which alignment of the liquid crystal layer 14 is uncontrollable. On an inner surface of the lower substrate 22 , a gate line 13 and a data line 15 cross the gate line 13 to define a pixel region P. A TFT T, which functions as a switching device, is disposed at crossing of the gate line 13 and the data line 15 . The TFT T includes a gate electrode 32 connected to the gate line 13 , a semiconductor layer 34 over the gate electrode 32 , a source electrode 36 connected to the data line 15 , and a drain electrode 38 spaced apart from the source electrode 36 . A pixel electrode 17 is connected to the TFT T. For example, the pixel electrode 17 is made of a transparent conductive material such as indium tin oxide (ITO).
[0007] A portion of the gate line 13 is utilized for a first capacitor electrode (not shown). A second capacitor electrode 30 is formed with the same material as the data line 15 . The first capacitor electrode, the second capacitor electrode 30 and a gate insulating layer 33 interposed therebetween constitute a storage capacitor C ST . Here, the second capacitor electrode 30 is connected to the pixel electrode 17 to be applied to a signal of the pixel electrode 17 .
[0008] A structure of the storage capacitor C ST may be variously modified.
[0009] In addition, a backlight unit 50 is disposed under the LCD panel 1 . The backlight unit 50 includes a cold cathode fluorescent lamp 52 as a fluorescent lamp, a lamp housing 54 covering the cold cathode fluorescent lamp 52 , a light guide panel 56 that converts light from the cold cathode fluorescent lamp 52 into a plan light, a reflector (not shown) under the light guide panel 56 to reflect light toward the LCD panel 1 , a diffusion sheet (not shown) diffusing light from the light guide panel 56 , first and second prism sheets (not shown) controlling a direction of the light for the first diffusion sheet, a protection sheet (not shown) protecting the sheets therebelow.
[0010] However, the LCD panel 1 is increasingly being manufactured as a light-weight, slimly-model, shaped mode, for example, such that a light emitting diode is suggested instead of the cold cathode fluorescent lamp 52 as the light source of the backlight unit 50 .
[0011] The light emitting diode can emit red, green and blue colors and can be manufactured as a small, slim and a light-weight device.
[0012] In addition, a field sequential color (FSC) driving method is suggested to obtain a high image quality with respect to an LCD device using a backlight unit having the mentioned light emitting diode emitting the red, green and blue colors. This FSC driving method may be defined such that red, green and blue colors are sequentially embodied and mixed with a time interval among the red, green and blue colors, thereby improving brightness in comparison with the related art driving method. Actually, in the FSC driving method, inputting data and the response speed of the liquid crystal material should be faster than the driving method according to the related art, which will increase brightness. However, there is a limitation to increasing brightness because the on-time of the backlight unit, except for inputting data and response time of the liquid crystal material, is limited.
[0013] To overcome these limitations, a tiling driving method, which is defined such that the LCD panel is independently driven in accordance with partitioned portions, is suggested.
[0014] FIG. 2 is a schematic plan view of an LCD device applying a tiling driving method according to the related art.
[0015] As shown in FIG. 2 , an LCD device 70 includes an active area A 1 displaying a picture and a driving area A 2 in a periphery with the active area A 1 . The LCD device 70 is partitioned top, bottom, right and left portions with respect to central line CL. Accordingly, as first and second source integrated circuit boards 72 a and 72 b are disposed in both the top and bottom portions and first and second gate integrated circuit boards 74 a and 74 b are disposed in the left portion, they are independently driven by the partitioned portions.
[0016] More specifically, the first and second gate integrated circuit boards 74 a and 74 b in the top and bottom portions with respect to the central gate line (not shown) are independently driven and scanning of the gate lines is begun from the central gate line. Here, top and bottom pixels of the central gate line are sequentially driven simultaneously.
[0017] As explained above, when the LCD panel is independently driven by the partitioned portions the inputting time of the data is reduced. Therefore, the response time and on-time of the backlight unit have an enough margin due to the reduction of inputting time.
[0018] Consequently, the LCD device applying the FSC driving method using partitioned driving can obtain high brightness.
[0019] FIG. 3 is an expanded plan view of a substrate of a FSC type LCD device applied a tiling driving method according to the related art.
[0020] As shown in FIG. 3 , a plurality of gate lines 82 and 82 a and a plurality of data lines 84 cross the plurality of gate lines 82 and define a plurality of pixel regions P on a substrate 80 . For example, the substrate 80 is made of a transparent insulating material. A plurality of thin film transistors T, T 1 and T 2 are formed at crossing points of the plurality of gate lines 82 and 82 a and the plurality of data lines 84 and are symmetrically formed with respect to a central gate line 82 s of the plurality of gate lines 82 and 82 a . Each of the plurality of thin film transistors T, T 1 , T 2 includes a gate electrode 86 , a semiconductor layer 88 , a source electrode 90 and a drain electrode 92 .
[0021] Here, the first and second thin film transistors T 1 and T 2 of the plurality of thin film transistors T, T 1 and T 2 are connected to the central gate line 82 a . Each of a plurality of pixel electrodes 94 is connected to the each of the plurality of the drain electrodes 92 . In other words, the first and second thin film transistors T 1 and T 2 adjacent to the central gate line 82 a are all connected to the central gate line 82 a . Therefore, the first and second thin film transistors T 1 and T 2 are simultaneously driven using the central gate line 82 a . Simultaneously, scanning signals are sequentially applied to top and bottom portions of the LCD panel 1 with respect to the central gate line 82 a.
[0022] A black matrix 96 is formed over the plurality of thin film transistors T, T 1 and T 2 to correspond to the plurality of gate lines 82 , 82 a , the plurality of data lines 84 and the plurality of thin film transistors T, T 1 and T 2 . The black matrix 96 is formed to prevent leakage current by shielding the plurality of thin film transistors from irradiation of the incident light. In addition, the black matrix 96 is formed to prevent a light leakage from the backlight unit by shielding an interval space between the plurality of pixel electrodes 94 and the plurality of gate and data lines 82 , 82 a and 84 .
[0023] That is, the black matrix 96 includes a first portion 96 a corresponding to the first and second thin film transistors T 1 and T 2 and a second portion 96 b corresponding to one of the plurality of thin film transistors except the first and second thin film transistors T 1 and T 2 . In other words, the black matrix 96 has different sizes corresponding to the plurality of thin film transistors T, T 1 and T 2 with respect to the central gate line 82 a such that the first portion 96 a is bigger than the second portion 96 b . Since the black matrix 96 has different portions between a portion of the central gate line 82 a and a portion of the other gate lines 82 except the central gate line 82 , it occurs as an image quality defect, such as a moiré phenomenon, and an image quality problem in that the central gate line 82 a is prominently shown. More specifically, the moiré phenomenon may be defined as an interference pattern, such as a ripple pattern, having a bigger period than an origin size when at least one pattern having a period in a space view.
[0024] Consequently, the moiré phenomenon of the interference pattern adjacent to the central gate line 82 a due to a size difference between the first and second portions 96 a and 96 b of the black matrix 96 may occur, thereby reducing the image quality of the display.
BREIF SUMMARY
[0025] Accordingly, the present invention is directed to an LCD device and a method of fabricating the LCD device that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0026] An object of the present invention is to provide an LCD device having a high image quality by preventing a moiré phenomenon and a problem such that the central gate line is prominently shown when an image of the LCD device is displayed.
[0027] Another object of the present invention is to provide a method of fabricating an LCD device having a high image quality by preventing a moiré phenomenon and a problem such that the central gate line is prominently shown when an image of the LCD device is displayed.
[0028] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0029] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a liquid crystal display device includes: a plurality of gate lines and a plurality of data lines crossing the plurality of gate lines to define a plurality of pixel regions on a first substrate; a plurality of thin film transistors at crossing points of the plurality of gate lines and the plurality of data lines, wherein the plurality of thin film transistors are symmetrically formed with respect to a central gate line of the plurality of gate lines, and wherein two groups of the plurality of thin film transistors are adjacent to the central gate line and are connected to the central gate line; a plurality of pixel electrodes connected to the plurality of thin film transistors, each of the plurality of pixel electrodes residing in each of the pixel regions; and a black matrix including a first portion overlapping the plurality of gate lines and the plurality of data lines, a second portion overlapping the plurality of thin film transistors, and a part that is integral with the first portion and renders the black matrix symmetrical with respect to the central gate line.
[0030] In another aspect, a method of fabricating a liquid crystal display device includes: forming a plurality of gate lines having a plurality of gate electrodes on a first substrate, wherein the first substrate has a plurality of pixel regions, wherein each of the plurality of gate electrodes are formed in each of the plurality of pixel regions, wherein two groups of the plurality of gate electrodes are adjacent to and directly connected to the central gate line; forming a plurality of data lines crossing the plurality of gate lines; forming a plurality of source electrodes connected to the plurality of data lines and a plurality of drain electrodes spaced apart from the plurality of source electrodes, wherein each of the plurality of gate electrodes, the plurality of source electrodes and the plurality of drain electrodes constitutes one of a plurality of thin film transistors, and wherein two groups of the plurality of thin film transistors adjacent to the central gate line are connected to the central gate line; forming a plurality of pixel electrodes connected to the plurality of thin film transistors, each of the plurality of pixel electrodes connected to the each of the plurality of drain electrodes; and forming a black matrix including a first portion overlapping the plurality of gate lines and the plurality of data lines and a first portion corresponding the plurality of thin film transistors, wherein a part is integral with the first portion and renders the black matrix symmetrical with respect to with respect to the central gate line.
[0031] In yet another aspect, a liquid crystal display device includes: a plurality of gate lines and a plurality of data lines crossing the plurality of gate lines that define the plurality of pixel regions that define a plurality of pixel regions on a first substrate; a plurality of thin film transistors each residing in a pixel region, wherein the plurality of thin film transistors are symmetrically formed with respect to a central gate line and wherein paired transistors reside on opposite sides of the central gate line; and a black matrix including a first portion overlying the central gate line and the paired transistors, a second portion overlying the plurality of thin film transistors, and an additional part that is integral with the second portion and renders the black matrix symmetrical with respect to the first portion.
[0032] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0034] FIG. 1 is a schematic cross sectional view of an LCD device according to the related art.
[0035] FIG. 2 is a schematic plan view of an LCD device applied a tiling driving method according to the related art.
[0036] FIG. 3 is an expanded plan view of a substrate of a FSC type LCD device applied a tiling driving method according to the related art.
[0037] FIG. 4 is a schematic cross sectional view of a FSC type LCD device applied a tiling driving method according to the present invention.
[0038] FIG. 5 is a schematic plan view of a FSC type LCD panel applying a tiling driving method according to the present invention.
[0039] FIGS. 6A to 6 F are schematic plan views in accordance with a fabricating process of an LCD device according to the present invention.
[0040] FIGS. 7A to 7 F are schematic cross sectional views taken along lines VII-VII of FIGS. 6A to 6 F, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] 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 the like parts.
[0042] FIG. 4 is a schematic cross sectional view of a FSC type LCD device applying a tiling driving method according to the present invention.
[0043] In FIG. 4 , an LCD panel LP includes a first substrate 100 , a second substrate 200 facing the first substrate 100 , and a liquid crystal layer 150 interposed therebetween. A backlight unit 350 is disposed under the LCD panel LP. A gate line 104 is formed on an inner surface of the first substrate 100 , a data line 116 crosses the gate line 104 to define a pixel region P. A thin film transistor T is connected to the gate line 104 and to the data line 116 at crossing point thereof, and a pixel electrode 122 is connected to the thin film transistor T in the pixel region P. In addition, a first capacitor electrode (not shown) resides in a portion of the gate line 104 , and a second capacitor electrode 118 , formed of the same material as the data line 116 , and a gate insulating layer 106 constitute a storage capacitor C ST .
[0044] A black matrix 204 is formed on an inner surface of the second substrate 200 and corresponds to the gate line 104 , the data line 116 , and the thin film transistor T except the pixel region P. A color filter layer 206 is formed on the inner surface of the second substrate 200 , more specifically, the color filter layer 206 includes red, green and blue color filters 206 a , 206 b and 206 c . Each of the red, green and blue color filters 206 a , 206 b and 206 c is disposed in the pixel region P. A common electrode 208 is formed over the color filter layer 206 and the black matrix 204 .
[0045] A light emitting diode 300 is disposed under the LCD panel LP and a diffusion plate 301 is disposed between the light emitting diode 300 and the LCD panel LP. Specifically, the diffusion plate 301 includes a first diffusion plate 302 over the light emitting diode 300 and a second diffusion plate 304 over the first diffusion plate 302 .
[0046] Although not shown, first and second gate integrated circuit boards are disposed at first and second areas in a periphery with an active area, respectively. First and second data integrated circuit boards may be disposed at third and fourth areas crossing the first and second areas in a periphery with an active area, respectively. The LCD device is independently driven by each of the first to fourth areas.
[0047] It is noted that the black matrix 204 includes a first portion overlapping the gate line 104 and the data line 116 and a second portion overlapping the thin film transistors T and a part integral with the first portion that renders the black matrix 204 symmetrical with respect to the central gate line 104 a . In other words, a formation portion of the black matrix 204 has a uniform size with respect to whole area of the LCD panel LP and is not depended on a formation position of the thin film transistor T.
[0048] FIG. 5 is a schematic plan view of a FSC type LCD panel applying to a tiling driving method according to the present invention.
[0049] As shown in FIG. 5 , a plurality of gate lines 104 and 104 a and a plurality of data lines 116 cross the plurality of gate lines 104 to define a plurality of pixel regions P on a first substrate 100 . For example, the first substrate 100 includes a transparent insulating material. A plurality of thin film transistors T, T 1 and T 2 are formed at crossing points of the plurality of gate lines 104 and 104 a and the plurality of data lines 116 and are symmetrically formed with respect to a central gate line 104 a of the plurality of gate lines 104 and 104 a . Each of the plurality of thin film transistors T, T 1 and T 2 includes a gate electrode 102 , a semiconductor layer 108 , a source electrode 112 and a drain electrode 114 .
[0050] More specifically, first and second thin film transistors T 1 and T 2 of the plurality of thin film transistors T, T 1 and T 2 adjacent to the central gate line 104 a are connected to the central gate line 104 a . A plurality of pixel electrodes 122 are connected to the plurality of thin film transistors T, T 1 and T 2 , each of the plurality of pixel electrodes 122 is formed in each of the pixel regions P.
[0051] Scanning signals are sequentially applied to two groups of the plurality of gate lines 104 and 104 a with respect to the central gate line 104 a.
[0052] A black matrix 204 overlaps the plurality of gate lines 104 and 104 a and the plurality of data lines 116 including an interval between the plurality of pixel electrodes 122 and the plurality of gate and data lines 104 , 104 a and 116 to shield leakage light from the backlight unit (not shown). In addition, the black matrix 204 overlaps the plurality of thin film transistors T, T 1 and T 2 to prevent a leakage current that causes mis-driving.
[0053] More specifically, the black matrix 204 includes a first portion overlapping the plurality of gate lines 104 and the plurality of data lines 116 and a second portion overlapping the plurality of thin film transistors T and a part AP that is integral with the first portion and renders the black matrix 204 symmetrical with respect to the plurality of thin film transistors T, and with respect to the plurality of the gate lines 104 and the central gate line 104 a.
[0054] Because the black matrix 204 is formed as a uniform structure that does not depend on the position of the plurality of thin film transistors T, T 1 and T 2 , the moiré phenomenon caused by the visibility of the central gate line 104 a is solved, thereby providing an LCD device having high image quality.
[0055] Here, the black matrix 204 may be formed on the first substrate 100 or a second substrate (not shown) facing the first substrate 100 .
[0056] FIGS. 6A to 6 F are schematic plan views in accordance with a fabricating process of an LCD device according to the present invention.
[0057] FIGS. 7A to 7 F are schematic cross sectional views taken along lines VII-VII of FIGS. 6A to 6 F, respectively.
[0058] In FIGS. 6A and 7A , a plurality of gate lines 104 and 104 a and a plurality of gate electrodes 102 connected to the plurality of gate lines 104 and 104 a are formed by depositing and patterning a conductive metallic material such as aluminum (Al), Al alloy, chromium (Cr), molybdenum (Mo), tungsten (W), and titan (Ti) on a first substrate 100 having a plurality of pixel regions P. Each of the plurality of gate electrodes 102 is disposed in each of the plurality of pixel regions P. Since the plurality of gate electrodes 102 are symmetrically formed with respect to the central gate line 104 a of the plurality of gate lines 104 and 104 a , the central gate line 104 a has two gate electrodes 102 oriented in opposite directions toward each of the plurality of pixel regions P.
[0059] Further, a gate insulating layer 106 is formed by depositing an inorganic insulating material such as silicon nitride and silicon oxide on an entire surface of the first substrate 100 .
[0060] In FIGS. 6B and 7B , a semiconductor layer 107 having an active layer 108 and an ohmic contact layer 110 is formed by sequentially depositing an intrinsic amorphous silicon layer and a doped amorphous silicon layer on the gate insulating layer 106 over the plurality of gate electrodes 102 .
[0061] In FIGS. 6C and 7C , a plurality of data lines 116 cross the plurality of gate lines 104 , a plurality of source electrodes 112 connect to the plurality of data lines 116 . A plurality of drain electrodes 114 , spaced apart from the plurality of source electrodes 112 , are formed by depositing and patterning a conductive metallic material such as Al, Al alloy, Cr, Mo, W, Ti and copper (Cu) over the semiconductor layer 107 . Each of the plurality of gate electrodes 102 , the plurality of source electrodes 112 and the plurality of drain electrodes 114 constitutes each of a plurality of thin film transistors T. First and second thin film transistors T 1 and T 2 adjacent to the central gate line 104 a are connected to the central gate line 104 a.
[0062] Next, a first portion of the active layer 108 between the source electrode 112 and the drain electrode 114 is exposed by removing a second portion of the ohmic contact layer 110 corresponding to the first portion of the active layer 108 . The exposed portion of the active layer 108 is defined as a channel CH.
[0063] In FIGS. 6D and 7D , a passivation layer 120 is formed by depositing an inorganic insulating material and coating an organic insulating material, such as a benzocyclobutene (BVB) and an acrylic resin, over the plurality of thin film transistors T. Next, a drain contact hole 121 is formed to expose a portion of the drain electrode 114 in the passivation layer 120 .
[0064] In FIGS. 6E and 7E , a plurality of pixel electrodes 122 are formed by depositing a transparent conductive material such as indium tin oxide (ITO) and indium zinc oxide (IZO) on the passivation layer 120 in the plurality of pixel regions P. Each of the plurality of pixel electrodes 122 are connected to the each of the plurality of drain electrodes 114 through each of the plurality of drain contact holes 121 .
[0065] In FIGS. 6F and 7F , a black matrix 204 is formed over the plurality of thin film transistors T, T 1 and T 2 and includes a first portion overlapping the plurality of gate lines 104 and 104 a and the plurality of data lines 116 , a second portion corresponding the plurality of thin film transistors T, T 1 and T 2 , and a part AP that is integral with the first portion and renders the black matrix 204 symmetric with respect to the plurality of thin film transistors T and with respect to the plurality of the gate lines 104 and the central gate line 104 a.
[0066] As shown in FIG. 7F , the black matrix 204 may be formed on a second substrate 200 facing the first substrate 100 . In this case, the black matrix 204 having the first and second portions is formed on an inner surface of the second substrate 200 . A color filter layer 206 is formed on the black matrix 204 and includes red, green and blue color filters 206 a , 206 b and 206 c , respectively, formed in accordance with the plurality of pixel regions P.
[0067] Next, a common electrode 208 is formed over an entire surface of the second substrate 200 having the black matrix 204 and the color filter layer 206 .
[0068] However, the black matrix 204 may be formed on the first substrate 100 having the plurality of gate lines 104 , the plurality of data lines 116 , and the plurality of thin film transistors T.
[0069] The black matrix 204 according to the present invention includes a first portion overlapping the plurality of gate lines and the plurality of data lines, a second portion corresponding the plurality of thin film transistors T, T 1 and T 2 , and a part AP that is integral with the first portion and renders the black matrix 204 symmetrical with respect to the plurality of thin film transistors T and with respect to the plurality of the gate lines 104 and the central ate line 104 a , thereby improving image quality preventing a moiré phenomenon and image defects caused by the visibility of the central gate line 104 a.
[0070] It will be apparent to those skilled in the art that various modifications and variations can be made in the liquid crystal display devices of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A liquid crystal display device includes: a plurality of gate lines and a plurality of data lines crossing the plurality of gate lines that define the plurality of pixel regions that define a plurality of pixel regions on a first substrate; a plurality of thin film transistors each residing in a pixel region, wherein the plurality of thin film transistors are symmetrically formed with respect to a central gate line and wherein paired transistors reside on opposite sides of the central gate line; and a black matrix including a first portion overlying the central gate line and the paired transistors, a second portion overlying the plurality of thin film transistors, and an additional part that is integral with the second portion and renders the black matrix symmetrical with respect to the first portion. | 6 |
BACKGROUND OF THE INVENTION
In hospitals and doctors' offices, blood samples are often taken from a person's arm so that various blood tests can be performed. To obtain a blood sample, the medical technician ("phlebotomist" herein) will ordinarily wrap a tourniquet about the patient's upper arm to cause veins in the distal portion of the arm to stand out, whereupon blood can be removed by means of a needle and syringe. The tourniquet which has long been used for this purpose is a length of stretchy rubber tubing which is passed about the upper arm and then knotted in place. This currently most popular tourniquet has a number of drawbacks, among which may be listed the possibility of disease transmission by reuse of the tourniquet near the sites of vein punctures, painful distortion of the skin by the knotting procedure, and injury by the inserted needle resulting from the jerk given to the tubing by a phlebotomist in attempting to release the knot after the needle has been inserted in a vein. Various other forms of tourniquets have been proposed in an effort to overcome at least the knotting problem, such tourniquets being reuseable and relatively expensive in terms of manufacturing costs. For example, in one such tourniquet, shown in U.S. Pat. No. 3,086,529, a pair of mating Velcro strips are sewn to respective ends of an elastic band. I am aware of no phlebotomist's tourniquet, other then the inexpensive length of flexible rubber tubing, which have enjoyed any significant measure of success or wide useage. The rubber tubing tourniquet remains to the present the most popular phlebotomist's tourniquet. A very inexpensive, throw-away or disposable tourniquet which can be easily used and which would avoid problems of disease transmission and trauma associated with the rubber tubing tourniquet is much to be desired.
SUMMARY OF THE INVENTION
The present invention relates to a disposable phlebotomist's tourniquet which comprises a supple, flat, elastic band which has bonded to one flat surface adjacent one end a non-stretchable pressure sensitive adhesive strip with a protective liner covering the adhesive strip during storage, the liner having a pull tab to facilitate peeling the liner away from the adhesive strip. The peel strength of the liner to the adhesive strip is less than the peel strength of the adhesive strip to the band so that when the liner is peeled away, the adhesive strip remains bonded to the band surface. The band is of a length permitting it, when stretched about the human upper arm, to have its ends well overlapped with a portion of the flat other surface of the stretched band coming into confronting relationship with the exposed adhesive surface of the adhesive strip and being bonded thereto to anchor the band in place about the arm. The non-stretchable adhesive strip and the surface of the band to which it is attached provide an adhesive surface of constant dimensions for receiving the confronting surface of the stretched band as the latter is wrapped around the arm.
DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a human arm showing the disposable tourniquet of the invention in place;
FIG. 2 is a perspective view of the disposable tourniquet of the invention with protective liner attached;
FIG. 3 is a partially broken away side view of the tourniquet of FIG. 2;
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 3; and
FIG. 5 is a partially broken away perspective view showing a portion of the tourniquet of the invention in stretched condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 2, the tourniquet of the invention is designated generally as 10, and includes a flat, elongated elastic band 12 having bonded adjacent one end 12.1 a substantially non-stretchable pressure-sensitive adhesive strip 14. The adhesive strip has its exposed adhesive surface covered with an easily removable liner 16 which may be a strip of plastic film or the like. One end 16.1 of the liner, desirably adjacent the end 12.1 of the band, protrudes beyond the adhesive strip to serve as a pull tab, the adhesive strip and liner being spaced inwardly slightly from the end 12.1 of the band so that the latter end can be gripped with fingers of one hand and the tab 16.1 may be gripped with the fingers of the other hand to permit the liner to be peeled away from the adhesive strip.
The band 12 is desirably a single length of inexpensive material such as latex rubber, plastic film, and the like. By "elastic" as used herein, reference is made to a material which may be stretched to a length greater than its original length and which also has the tendancy to return, at least slightly, toward its original length when stretching force is removed. Although only very slightly stretchable materials may be used for the band 12, it is desired that the band material be stretchable to a length of at least about 120 percent of its original length, and preferably 150 percent of its original length without breaking. It is the elasticity, as this term is used herein, of the band 12 which causes the tourniquet of the invention to be snuggly held about a human limb to cause veins distal of the tourniquet to stand out, and hence completely inextensible materials are not desirable for use as the band material. Bias-cut woven cloth, knit cloth, and fabric having elastic strings therethrough are other examples of materials suitable for use as the band 12. Desirably, however, the band is made from a non-woven material such as rubber or plastic. The length of the band in its unstretched state is such that when the band is stretched around the upper arm, the other end 12.5 of the band will completely overlap the adhesive strip 14, leaving the terminal portion of the other end 12.5 of the band hanging loosely as shown in FIG. 1. If an easily stretchable material, such as thin latex rubber sheeting, is employed as the band material, then the minimum length of the band can be relatively short; eg., 8 or 9 inches. If the band is of a material or thickness such that relatively great force is required to stretch the band, the minimum length of the band must be somewhat longer, eg., 15-20 inches. A band of latex rubber 14 inches in length with width and thickness dimensions of 1 inch and 0.020 inches, respectively, has yielded excellent results. Preferably, the length of the band is in the range of about 12 to about 16 inches. The band should additionally be of sufficient width so that when it is stretched and wrapped about the arm, the band has a sufficient area of surface-to-surface contact with the skin to avoid cutting into or otherwise bruising the flesh of the arm. A width of approximately 1 inch is desired, although slightly greater or lesser widths may also be employed. The thickness of the band, and the band material, should be such that the band itself is limp and drapable, rather than relatively stiff. When the band is stretchingly wrapped about the arm during use, the band should "cup" slightly so that a cross section of the band taken transversely of its length shows the band to be concave outwardly. The longitudinal edges of the band are thus prevented from digging into the flesh. The limpness, or drapability, associated with a latex rubber sheet 0.020 inches in thickness, or a highly plasticized polyvinylchloride film 0.002 inches in thickness, is appropriate for band materials of the present invention.
The adhesive strip 14 is desirably slightly narrower than the band 12 so that contact of the adhesive with the skin is avoided. In the embodiment referred to above in which a latex rubber band one inch in width was employed, an adhesive strip three-fourths of an inch wide and 21/2 inches long provided very good results, the adhesive strip being centered adjacent the end 12.1 of the band so as to provide 1/8 inch margins between the longitudinal edges of the adhesive strip and the adjacent edges of the band. The adhesive strip is spaced slightly inwardly, eg. 3/4 inches-1 inch, from the one end 12.1 of the band so that this end of the band may be grasped between the fingers without contacting adhesive. The adhesive strip is relatively non-stretchy, and may include an internal reinforcement such as a length of relatively inextensible plastic film. In the embodiment depicted in FIG. 4, the adhesive strip is of the construction designated collectively as 14 and includes an inner, non-extensible plastic film 14.2 sandwiched between two layers of pressure sensitive adhesive. The plastic film 14.2 may be polyester, cellophane, strong paper, or other material. Of importance is the fact that the stretchability, that is, the ease of stretching, of the adhesive strip must be less than that of the band 12. This feature permits the end of the tourniquet bearing the adhesive strip to assume the configuration shown in FIG. 5 when the tourniquet is stretched, the adhesive strip 14 and that section of the band to which the adhesive strip is bonded retaining constant dimensions whereas the band material itself has a tendancy to neck down as shown at 12.3 in FIG. 5.
The adhesive which is employed in the adhesive strip is of the pressure sensitive variety known to the adhesive art and employed in adhesive tapes such as surgical tapes. The adhesive should be readily adherent to the opposed flat surface of the band, and the adhesive bond which is formed during use of the tourniquet should have relatively high shear strength. Although hypoallergenic adhesives are desired, such adhesives are not critical to the invention since the adhesive itself does not touch the skin when the tourniquet of the present invention is correctly used. It is desired, however, that the adhesive be nontoxic and nonirritating to normal skin.
Over the outer, or exposed, layer of adhesive 14.3 is positioned a peel-away liner 16. The purpose of the liner is to protect the outer surface of the adhesive layer 14.3 during packaging and storage, and the liner 16 is stripped away and discarded just before the tourniquet of the invention is to be applied to the arm. The surface of the liner which contacts the adhesive layer 14.3 should adhere poorly to this adhesive layer so that when the liner is peeled away, the adhesive strip 14 in its entirety remains with the band 12. Silicone treated release paper has given excellent results, and other materials which may be used include various low-adhesion plastic films such as films of polyethylene, polytetrafluoroethylene (Teflon TFE, a product of the DuPont Company), etc. The force required to peel the liner from the adhesive strip 14 must be less than the force required for cohesive failure of the adhesive strip and must also be less than the force required to peel the adhesive strip from the band 12. Use may be made of various known coatings on the liner to decrease the adhesion between liner and adhesive, and various materials may be employed to increase adhesion between the adhesive strip and the band 12. Thus, a wide variety of adhesives and liners may be employed, and those skilled in the adhesive art will be able to readily select an appropriate adhesive and liner for use in the present invention.
A tourniquet of the invention may be made by hand, as by providing a length of latex rubber sheeting, applying to one end thereof the adhesive strip 14, and thereover applying the liner 16. The manufacture of tourniquets of the invention may readily be automated; for example, a roll of adhesive strip material approximately 21/2 inches wide and having the construction shown in FIG. 4 may be provided with a continuous length of liner 16 along one adhesive surface with the edge of the liner protruding slightly from the side of the adhesive strip, the adhesive material thereafter being laminated to and along one edge of a length of band material having a width of approximately 14 inches. The resulting laminate may then be transversely cut into one inch lengths. Various other manufacturing methods will be apparent to the skill artisan.
In use, the pull tab 16.1 of the liner of a tourniquet of the invention is grasped between the fingers of one hand, with the terminal end 12.1 of the band being held by the other hand, and the pull tab is pulled backward to peel away the liner 16. The end 12.1 of the band is then pressed against the skin of the bared upper arm with one hand, while with the other hand the operator stretches the other end 12.5 of the band around the arm, the adhesive strip 14 being on the outside. When the band is stretched fully about the upper arm with the desired tightness, that portion of the surface of the band which comes into confronting relationship with the adhesive strip 14 is pressed against the strip, and the tourniquet is thus held in place. The end 12.5 of the tourniquet extends beyond the adhesive bond thus formed, and hangs loose as shown in FIG. 1. When a needle has been inserted into a vein distally of the tourniquet so that blood may be removed, then the tourniquet may be gently removed from the arm without jarring by simply pulling the end 12.5 of the band away from the arm gently, peeling apart the adhesive bond and permitting the tourniquet to fall loosely away from the arm. In this manner, little if any twisting or jerking motion is imparted to the arm which would result in injury to arm tissues by the needle. The tourniquet, being of very inexpensive material, can thereafter be discarded. If desired, the tourniquets of the invention may be rendered sterile before use by treatment with heat or a sterilizing gas.
Manifestly, I have provided a disposable tourniquet of inexpensive manufacture which reduces the possibility of disease transmission and which may be employed with minimal, if any, tissue damage of the type associated with the use of popular rubber tubing tourniquets.
While I have described a preferred embodiment of the present invention, it should be understood that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | A disposable phlebotomist's tourniquet comprising a flat solid, elastic band of a length sufficient, when stretched, to encircle the human upper arm and including adjacent one end a relatively non-stretchable pressure-sensitive adhesive strip protectively covered for storage by a protective liner of treated paper or the like having one end projecting beyond the end of the adhesive strip as a graspable pull tab so that the liner may be pulled away. | 0 |
BACKGROUND
1. Technical Field
The present disclosure relates to display devices. More specifically, the present disclosure relates to a holder for displaying a sheet of material that may be customized for a particular purpose and then changed on an as needed basis.
2. Background of the Related Art
Display holders are used to display information, including advertising or name information. Furthermore, these holders must be able to receive and firmly secure the material received within the holder but also be easily changed if such material in the holder needs to be updated or amended. For example, with advertising material, it is sometimes desirable to change or update the information displayed or the sheet of material on a regular or as needed basis.
Accordingly, it is an aspect of the present disclosure to provide a holder suitable for displaying a sheet of material that can be customized for a particular purpose but also removed and replaced if such purpose has changed.
SUMMARY
A holder for displaying a sheet of material is disclosed having a backplate and a removable lens adjacent to the backplate. The backplate is secured to a bracket using at least one fastening member, such as a screw or rivet. The bracket includes a mechanism for supporting the lens and a sheet of material between the backplate and the lens. The mechanism includes at least one protrusion or peg configured and dimensioned for connecting to at least one connector of the lens and the sheet of material.
In particular, the holder includes a backplate, a lens, and a bracket. The bracket includes a frame defining at least one vertical wall bordering at least one inner wall. The at least one inner wall includes at least one connector for connecting to at least one corresponding connector of the lens for securing the lens to the bracket. A portion of the lens contacts a first wall of the at least one vertical wall and a first inner wall of the at least one inner wall. The backplate is secured to the bracket via at least one fastener. A portion of the backplate contacts a second wall of the at least one vertical wall and a second inner wall of the at least one inner wall.
According to the present disclosure, a kit is also provided. The kit includes a plurality of brackets, a plurality of backplates, and/or a plurality of lenses. The brackets, lenses and/or the backplates of the kit can be assembled in a plurality of combinations. Additionally, the brackets, lenses and/or the backplates of the kit can be tinted different colors, have difference sizes, etc. to enable the creation of a variety of visual effects and different assembled holders.
BRIEF DESCRIPTION OF THE DRAWINGS
Particular embodiments of the presently disclosed holder are described herein with reference to the drawings, wherein:
FIG. 1 shows an exploded perspective view of an embodiment of a holder for displaying a sheet of material in accordance with the present disclosure;
FIG. 2 shows a front view of a sheet of material capable of being displayed by the holder of FIG. 1 ;
FIG. 3 shows a front view of a lens or front plate of the holder shown in FIG. 1 ;
FIG. 4 shows a perspective view of a bracket of the holder shown in FIG. 1 ;
FIG. 5 shows a front view of a backplate of the holder shown in FIG. 1 .
FIG. 6A shows a perspective view of the holder shown in FIG. 1 showing the lens removed from the bracket-backplate assembly;
FIG. 6B shows a perspective view of the holder shown in FIG. 1 showing the lens supported or connected to the bracket-backplate assembly;
FIG. 6C shows a perspective view of the backside of the holder shown in FIG. 1 showing the connection of the lens to the bracket-backplate assembly; and
FIG. 7 shows an exploded perspective view of an alternate embodiment of a holder for displaying a sheet of material in accordance with the present disclosure.
DETAILED DESCRIPTION
Embodiments of the a holder for displaying a sheet of material are described below in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.
Referring to FIG. 1 , there is shown an exploded view of a holder for displaying a sheet of material therein according to an embodiment of the present disclosure. The holder is generally identified by reference numeral 100 . Holder 100 includes a bracket 102 , a lens or front plate 110 , and a backplate 120 . The bracket 102 includes a frame 104 bordering on three sides an inner securing wall 109 and bordering on two sides an inner connecting wall 107 .
The frame 104 defines a first vertical wall 103 bordering the inner securing wall 109 on the three sides. The frame further defines second vertical walls 105 a , 105 b on two opposing sides of the inner connecting wall 107 . The second vertical walls 105 a , 105 b partially including the first vertical wall 103 and having substantially twice the width of the first vertical wall 103 .
A third vertical wall 111 having substantially the same width as the first vertical wall 105 provides a separation between the inner connecting wall 107 and the inner securing wall 109 . The bracket 102 further includes a fourth vertical wall 113 at an edge of the inner connecting wall 107 . The inner connecting wall 107 is at a step-down configuration with respect to the inner securing wall 109 .
The connecting wall 107 of the bracket 102 includes two connectors, such as pegs or protrusions 106 a , 106 b , configured for being received by corresponding connectors, such as J-hooks 116 a , 116 b , of the lens 110 as further described below. The pegs 106 a , 106 b are also used for connecting thereto two J-hooks 171 a , 171 b ( FIG. 2 ) provided on a sheet of material 170 for holding the sheet of material 170 as also further described below.
The bracket 102 further includes two openings 108 a , 108 b for attaching to the backplate 120 via two fastening members 130 a , 130 b , such as screws or rivets. The holder 100 is configured to be mounted to a support surface such as a wall, door, etc. via an adhesive, or one or more fastening members, such as screws, pins, etc.
Referring to FIGS. 2-6C , a discussion will now be presented regarding one method of assembly of the various components of the holder 100 shown in FIG. 1 . First, the sheet of material 170 is mounted on the bracket 102 via pegs 106 a , 106 b being connected to J-hooks 171 a , 171 b of the sheet of material 170 . Upon mounting to the bracket 120 , a portion of the material 170 rests on connecting wall 107 . The sheet of material 170 can be paper, metallic, plastic, or other type of material having indicia, text, pictures, logos, markings, codes, etc. thereon for display by the holder 100 .
Second, the backplate 120 is fastened to the bracket 102 using fastening members 130 a , 130 b to form a bracket-backplate assembly. The fastening members 130 a , 130 b traverse openings 122 a , 122 b of the backplate 120 and are threaded or fitted within openings 108 a , 108 b of the bracket 102 . Once the backplate 120 is fastened to the bracket 102 , a portion of the backplate 120 rests against the inner securing wall 109 of the bracket 102 and is flush with respect to the frame 104 and the top surface of each peg 106 .
Third, the lens 110 is mounted to the bracket-backplate assembly. Each of the J-hooks 116 a and 116 b of the lens 110 includes an opening for receiving therein a corresponding peg 106 of the bracket 102 . The lens 110 , after the pegs 106 a , 106 b are received within the openings of the J-hooks 116 a , 116 b , is slided or positioned towards a bottom portion of the connecting wall 107 against the second vertical wall 105 a of the bracket 102 . An edge of the lens 110 abuts the third vertical wall 111 and is flush with respect to the third vertical wall 111 .
When the holder 100 is fully assembled, each of the pegs 106 a , 106 b having outer surfaces 140 a , 140 b rests on a curved portion of a respective J-hook 116 as shown by FIG. 6C . A different connection mechanism, other than the J-hook 116 mechanism, can be provided to holder 100 .
The lens 110 and/or sheet of material 170 can be easily removed from the bracket-backplate assembly without disconnecting the bracket-backplate assembly. The final assembly of the holder 100 , as shown by FIGS. 6B and 6C , has the lens 110 substantially overlaying the backplate 120 .
The lens 110 is constructed of a transparent material, such as plastic, acrylic, and glass, including transparent magnifying materials, as is necessary for viewing the sheet of material 170 between the lens 110 and the backplate 120 . It is contemplated, however, that the lens 110 is constructed of other materials, including non-transparent materials, and that the lens 110 is provided with indicia, text, pictures, logos, markings, codes, etc. In this embodiment, the lens 110 acts as the display of indicia, text, pictures, logos, markings, codes, etc., and a sheet of material 170 does not have to be provided between the lens 110 and the backplate 120 .
It is also contemplated that the lens 110 is provided with indicia, text, pictures, logos, markings, codes, etc., as well as the sheet of material 170 and/or the backplate 120 . As a result, the lens 110 in combination with the sheet of material 170 and/or the backplate 120 acts as the display for the indicia, text, pictures, logos, markings, codes, etc. It is further contemplated that the backplate 120 is provided with indicia, text, pictures, logos, markings, codes, etc., as well as the sheet of material 170 and/or the lens 110 . As a result, the backplate 120 in combination with the sheet of material 170 and/or the lens 110 acts as the display for the indicia, text, pictures, logos, markings, codes, etc.
The dimensions of the various components can be altered to provide holders 100 of various sizes to accommodate sheets of material 170 of various sizes, in accordance with the present disclosure and as described below with reference to FIG. 7 . The sheet of material 170 can be customized to be the same or different size than the size of the lens 110 , and/or also have J-hooks as the lens 110 for connecting to the pegs 106 a , 106 b of the bracket 102 .
In accordance with the present disclosure, the holder 100 can be packaged as a kit having a plurality of brackets 102 , a plurality of lenses 110 , and/or a plurality of backplates 120 . Each of the plurality of backplates 120 and lenses 110 can be tinted different colors, or be transparent, opaque, etc. enabling the user to remove the backplate 120 of the holder 100 and/or lens 110 and replace one or both with another backplate 120 or lens 110 provided by the kit.
With reference to FIG. 7 , there is shown an exploded view of another holder 200 for displaying a sheet of material 270 according to the present disclosure. The holder 200 has features identical to holder 100 but a different size. The holder 200 , as with holder 100 , includes a lens 210 through which the sheet of material 270 can be viewed.
The lens 210 may be generally rectangular in shape and constructed from a transparent or non-transparent material as is necessary for viewing the sheet of material therethrough, and as described above with respect to lens 110 . A backplate 220 is shaped to substantially correspond to the rectangular shape of the lens 210 , and be mounted to a bracket 202 in a similar manner as described above with respect to backplate 120 and bracket 102 .
The bracket of holder 200 has three pegs 206 a - c , and the lens 210 of bracket 202 has three J-hooks 212 a - c for respectively mounting to the three pegs 206 a - c of the bracket 202 .
It would be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those in the art which are also intended to be encompassed by the following claims. | A holder for displaying a sheet of material is provided. The holder includes a backplate, a lens, and a bracket. The bracket includes a frame defining at least one vertical wall bordering at least one inner wall. The at least one inner wall includes at least one connector for connecting to at least one corresponding connector of the lens for securing the lens to the bracket. A portion of the lens contacts a first wall of the at least one vertical wall and a first inner wall of the at least one inner wall. The backplate is secured to the bracket via at least one fastener. A portion of the backplate contacts a second wall of the at least one vertical wall and a second inner wall of the at least one inner wall. | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to book lights and in particular to a novel and highly effective book light that provides better illumination and, in a preferred embodiment, longer service than those available heretofore.
[0002] A conventional book light illuminates a page or two of reading matter without substantially illuminating the surrounding area. This enables a user of the book light to read without disturbing those nearby. Such a device is well suited for reading in bed or while using public transportation.
[0003] Conventional book lights have added greatly to the convenience of reading while traveling or in bed; and the inventor has discovered that the illumination they provide can be further enhanced by an improvement that may also greatly extend the intervals between minor repairs or adjustments.
SUMMARY OF THE INVENTION
[0004] One object of the invention is to enhance the illumination provided by book lights. Another is to make book lights more user-friendly by reducing the amount of minor servicing they require.
[0005] These objects and others are attained in one embodiment of the invention by providing a book light comprising a base, an arm having proximal and distal ends, and a light source. The proximal end of the arm is pivotally connected to the base, and the light source is pivotally connected to the distal end of the arm and comprises at least one light-emitting diode (LED).
[0006] In another embodiment of the invention, the light source comprises at least two light emitters, preferably both LED's.
[0007] The invention provides a number of advantages. The provision of at least two light emitters, whether LED's or another kind of emitter, increases the light otherwise available, which helps older readers especially. Despite the small size of a book light and the consequent close spacing of the light emitters, it also enables one light emitter to fill in shadows cast by the other. So the light provided is not only brighter, but also softer or more diffuse. Moreover, the use of LED's provides, in comparison to many conventional light bulbs, a high light flux in relation to the electrical current drawn. That is especially advantageous in the case of book lights that are intended, as most are, to be powered at least part of the time by batteries. In accordance with the invention, conventional batteries are good for 12 to 14 or even 20 hours of continuous service. LED's also have the advantage, in comparison to most conventional light bulbs, of an extremely long life—as much as 100,000 hours of continuous service. These innovations make a book light constructed in accordance with the invention better for reading, easier to maintain, and therefore much more desirable.
BRIEF DESCRIPTION OF THE DRAWING
[0008] A better understanding of the objects, features and advantages of the invention can be gained from a consideration of the following detailed description, in conjunction with the appended figures of the drawing, which show several configurations of different embodiments of a book light constructed in accordance with the invention. In the drawing:
[0009] FIG. 1 is a perspective view of one embodiment of a book light constructed in accordance with the invention, the book light being in a first configuration wherein it is adapted for deployment;
[0010] FIG. 2 is a right side view of the structure of FIG. 1 , the book light being in a second configuration wherein it is adapted for storage;
[0011] FIG. 3 is a top view thereof in the second configuration;
[0012] FIG. 4 is a front view thereof in the second configuration;
[0013] FIG. 5 is a rear view thereof in the second configuration;
[0014] FIG. 6 is a bottom view thereof;
[0015] FIG. 7 is a partly sectional right side view thereof in the first configuration;
[0016] FIG. 8 is a fragmentary bottom view showing a battery compartment included in a base of the book light;
[0017] FIG. 9 is a top view showing one arrangement of LED's in accordance with the invention;
[0018] FIG. 10 is a right side view showing the book light cooperating with a book;
[0019] FIG. 11 is a perspective plan view of another embodiment of a book light constructed in accordance with the invention; and
[0020] FIG. 12 is a side view of the embodiment of the invention shown in FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] FIG. 1 shows a book light 10 constructed in accordance with one embodiment of the invention. It comprises a base 12 that has a spring clip 14 and is pivotally connected to the proximal end 16 of a straight telescoping arm 18 . The pivoting movement of the arm 18 relative to the base 12 is illustrated by a curved, double-headed arrow A 1 in FIG. 7 .
[0022] The arm 18 comprises a first portion 20 and a second portion 22 that, in one embodiment of the invention, slides within the first portion, as illustrated by a straight, double-headed arrow A 2 in FIG. 7 . But for purposes of the invention, the second portion 22 can slide within the first 20 , the first portion 20 can slide within the second 22 , or the two portions 20 , 22 can have U-shaped cross sections that open towards each other so that each arm portion 20 , 22 is partly inside and partly outside the other.
[0023] A shade 24 , which can be opaque or translucent, is pivotally mounted at the distal end 26 of the second portion 22 , which is also the distal end of the arm 18 . The shade 24 can be pivoted, as indicated by a small, curved, double-headed arrow A 3 in FIG. 7 . At least one and preferably two light-emitting diodes (LED's) 28 , 30 ( FIGS. 7 and 9 ) are mounted within the shade 24 . The emitted light will normally be white but can be of any desired color. The shade directs the light emitted by the LED's 28 , 30 towards a book or other object to be illuminated and shields the eyes of a user of the book light 10 and those of other people in the vicinity from light glare from the LED's 28 , 30 .
[0024] The clip 14 enables removable attachment of the book light 10 to a book 32 or other object to be illuminated, as illustrated in FIG. 10 . The proximal end 34 of the clip 14 is integral with the base 12 , to which it is attached by screws 35 , and the distal end 36 is curved up (away from the base 12 ) so that it easily slips over the top of pages inserted between the clip 14 and the base 12 . The clip 14 acts as a spring and securely grips the inserted pages to hold the book light 10 in a desired position relative to the book 32 or other object to be illuminated. Stable positioning of the book light in this manner is facilitated by its low weight, which can be as little as a few tens of grams.
[0025] The arm 18 is hollow and houses conductors 36 , 38 ( FIG. 7 ) that supply power from batteries 40 to the light emitters 28 , 30 . The conductors 36 , 38 can be constructed so that they are continuous from the batteries 40 to the light emitters 28 , 30 when the arm 18 is extended as in FIG. 1 but interrupted when the distal end 26 of the arm 18 is telescoped into the proximal end 16 as in FIG. 2 . In that case, extending the arm 18 to the configuration shown in FIG. 1 turns the book light 10 on, and collapsing it to the configuration shown in FIG. 2 turns it off.
[0026] It is also within the scope of the invention to provide a separate switch and conductors that are continuous within the arm in all configurations of the book light 10 so that the light emitters 28 , 30 can be turned on or off regardless of the extension or retraction of the arm 18 . This gives an additional degree of freedom in positioning the emitters 28 , 30 with respect to reading matter or another object to be illuminated.
[0027] The batteries 40 are accommodated within a battery compartment 42 formed in the base 12 . Access to the battery compartment 42 is provided by a door or panel 44 ( FIG. 6 ). The number and type of batteries 40 employed can be varied in accordance with design requirements. In FIG. 8 , four AAA batteries 40 are illustrated, which are light in weight and inexpensive yet capable of giving long service—as much as 20 hours—before requiring replacement, especially since LED's do not make heavy power demands. Rechargeable batteries can optionally be provided, together with a charger that can be connected to house current for recharging the batteries. It is even possible to construct a book light in accordance with the invention that does not employ batteries but is powered solely by house current through a step-down transformer.
[0028] The pivoting movement of the arm 18 relative to the base 12 and of the shade 24 and light emitters 28 , 30 relative to the arm 18 , and the adjustable extension of the arm 18 give great flexibility to a book light 10 constructed in accordance with the invention. In use, it is very easy to position the emitters 28 , 30 for optimal illumination of a book or another object to be illuminated while shielding the eyes of a user of the book light 10 and of those of others in the vicinity from the glare of the emitters 28 , 30 . A book light 10 constructed in accordance with the invention is thus ideally suited for reading in bed or for use while traveling or in any other setting where private illumination without disturbing neighbors is desired.
[0029] In one embodiment of the invention, a shade 24 ′ that is rectangular in plan view ( FIGS. 11 and 12 ) cooperates with the light source 28 , 30 to cast a more-or-less pyramidal light wedge. That can be an advantage where the goal is to cast a light wedge having a cross section that conforms generally to the shape of reading matter to be illuminated.
[0030] In embodiments of the invention wherein the shade is circular in plan view ( FIGS. 1-10 ), the shade 24 cooperates with the light source 28 , 30 to cast a more-or-less conical light wedge. That can be an advantage where the goal is to cast a light wedge having a cross section that is more-or-less radially symmetrical about its center.
[0031] Different patterns of side-by-side emitters 28 , 30 are within the scope of the invention, including one wherein they are longitudinally displaced relative to the arm 18 , as in FIG. 9 ; one wherein they are transversely displaced relative to the axis of the arm 18 , and one wherein they are diagonally displaced relative to that axis. One can also provide three or more light emitters. In the case of three emitters, they can be arranged linearly (extending in any direction) or in a triangular configuration.
[0032] Thus there is provided in accordance with the invention a novel and highly effective book light that fully attains the objects of the invention. It enhances the illumination provided by book lights by making the light at once brighter and softer or more diffuse, thereby making reading easier and at the same time reducing eyestrain It also makes book lights more user-friendly by reducing the amount of minor servicing they require. In particular, it is unlikely that many users would ever need to replace the LED's.
[0033] The embodiments of the invention disclosed herein are merely exemplary, and many modifications and elaborations thereof will readily occur to those skilled in the art. For example, plastics, metals and other materials can be used to make book lights according to the invention, and the shape of the base 12 , clip 14 , arm 18 and shade 24 can be varied without exceeding the scope of the invention. The invention is defined only by the appended claims, which include all structure that falls within their scope, plus equivalents thereof. | A book light has a base, a telescoping arm having proximal and distal ends, and a shaded light source. The proximal end of the arm is pivotally connected to the base, and the light source is pivotally connected to the distal end of the arm. The light source includes at least one and preferably two light-emitting diodes (LED's). The resulting book light seldom requires attention and sheds a light that is both brighter and more diffuse and therefore better suited for reading than the light provided by a conventional book light. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to power generators and more specifically it relates to a wind or water turbine with fins that rotate independently to maximize power generation.
[0003] The present invention is a wind or water powered turbine comprising stationary plates having an off-center power shaft with pairs of radially extending arms fastened thereto with bearing supported transverse shafts having fixed fins with roller bearings positioned on each corner of the fin side engaging a stationary plate. Each of the stationary plates has a track with one of the fins roller bearings contained thereby. Also positioned on the interior side of each of the stationary plates is a pivotal switch for re-orienting the fin during its elliptical path along the periphery of the stationary path with the object of having one fin in a vertical position receiving the full force of the wind or water on its vertical face while the fin on the opposite side being in a horizontal position receives a force only on its edge.
[0004] The stationary plate channel provides means for encapsulating a lead bearing fixedly attached to each fin allowing the fin to transverse around a centralized pivot point. Upon rotation about the channel the encapsulated lead bearing reaches a transfer pivot switch that forces the lead bearing out of the channel while leading a trailing bearing or (free bearing) fixedly attached to the opposing end of the fin into the channel.
[0005] With the transferring of the lead bearing out of the channel and the free bearing into the channel optimal fin position is obtained to provide maximum power to the main shaft and thus improved generation of power. Thus upon each time the lead bearing of the fin reaches the transfer switch, the lead bearing is converted into the free bearing and the free bearing is converted into the lead bearing. Utilizing this system of the present invention in a four fin configuration, 90 degrees apart, upon rotation of each revolution three of the four fins are in constant generation of power while the forth fin is positioned to minimize drag.
[0006] 2. Description of the Prior Art
[0007] There are other wind and water turbines. Typical of these is U.S. Pat. No. 4,517 issued to Hand on May 16, 1846.
[0008] Another patent application was issued to Pallausch on Jul. 29, 1884 as U.S. Pat. No. 302,769. Yet another U.S. Pat. No. 391,539 was issued to Lard on Oct. 23, 1888 and still yet another was issued on Jun. 26, 1945 to Topalov as U.S. Pat. No. 2,379,324. Another patent was issued to Soules on Jan. 25, 1977 as U.S. Pat. No. 4,004,861.
[0009] Yet another U.S. Pat. No. 4,380,417 was issued to Fork on Apr. 19, 1983. Another U.S. Pat. No. 4,411,591 was issued to Hesting on Oct. 25, 1983 and still yet another was issued on Oct. 11, 1988 to Blowers as U.S. Pat. No. 4,776,762. Another patent was issued to Rademacher on Sep. 24, 1991 as U.S. Pat. No. 5,051,059 and still yet another was issued on Dec. 28, 1999 to Geary as U.S. Pat. No. 6,006,518.
[0010] Another patent application was issued to Downing on Dec. 31, 2002 as U.S. Pat. No. 6,499,939. Yet another U.S. Pat. No. 7,090,553 was issued to Seiford on Aug. 15, 2006.
[0011] Internationally, a Russian patent was issued to Bojarshinov as Russian Patent No. RU2016220 on Jul. 15, 1994. An International Patent Application was published to Castaneda Mungi on Oct. 7, 2004 as World Publication No. WO2004/085841.
U.S. Pat. No. 4,517
Inventor: Christopher Hand
Issued: May 16, 1846
[0012] This is a new and useful improvement in water-wheels, and that the following is a full, clear, and exact description of the principle or character thereof, which distinguishes it from all other things before known, and of the manner of making, constructing, and using the same, reference being had to the accompanying drawings, making part of this specification.
U.S. Pat. No. 302,769
Inventor: Franz Pallausch
Issued: Jul. 29, 1884
[0013] This invention has reference to an improved paddle-wheel which may be used either as a water-wheel, or as a wind-motor, or as a ventilator, and which may be mounted either horizontally or vertically and worked at any level of the water and in a state of total submersion.
U.S. Pat. No. 391,539
Inventor: Shelden B. Lard
Issued: Oct. 23, 1888
[0014] The invention consists of a water wheel provided with a series of overlapping leaves or buckets pivoted a little at one side of their center, and with a series of loosely pivoted and sliding catches for engaging the leaves or buckets when folded, to lock them closed. The invention also consists in the peculiar construction and arrangement of parts, all as hereinafter fully described, and pointed out in the claims.
U.S. Pat. No. 2,379,324
Inventor: Michael S. Topalov
Issued: Jun. 26, 1945
[0015] This invention relates either to water or to wind power motors which are composed of two or more rotors turning about vertical axes in opposite directions, and is a modification of the stream motors disclosed in my previous application Ser. No. 316,149 filed in the U.S. Patent Office Jan. 29, 1940, Division 9, room 4624. It is an object of my invention to provide a simple and efficient rudderless motor to utilize either the wind or the natural flow of water without the aid of dams or the like.
U.S. Pat. No. 4,004,861
Inventor: Charl Soules
Issued: Jan. 25, 1977
[0016] A wind driven prime mover which is driven by a plurality of arcuately shaped wind vanes pivotally mounted on a rotatable turntable. The wind vanes are pivotally mounted on the turntable with their pivot axle disposed in a vertical plane. The pivots are positioned adjacent the periphery of the turntable, with the pivots being spaced equidistant from each other and equidistant from the axis of rotation of the turntable. The bottoms of the vanes are arcuately shaped, with the length of the arc being slightly longer than the space between the pivots so that there is an overlap between adjacent vanes. The convex surface of the vanes face outwardly to provide a concave inner surface.
U.S. Pat. No. 4,380,417
Inventor: Werner Fork
Issued: Apr. 19, 1983
[0017] An installation for extracting useful work, such as driving an electric generator from a fluid stream, includes a platform rotatable about a central axis and supporting a plurality of blades or vanes, each of which is rotatable about its individual blade axis to vary the angle of attack between the blades and the fluid stream during each revolution of the platform. The blades are coupled together so that each blade executes a similar motion during each platform revolution and so that the angle of attack of the fluid stream relative to a given blade is substantially zero when the fluid stream direction is perpendicular to the plane including the central platform axis and the axis of the given blade, the amount of variation in blade angle of attack during each revolution is variable to compensate for variations in the fluid flow.
U.S. Pat. No. 4,411,591
Inventor: Daniel O. Hesting
Issued: Oct. 25, 1983
[0018] A power turbine employs a plurality of turbine blades each having a normal lip mounted at the free ends thereof. The plurality of turbine blades are mounted in a paddle wheel type configuration about the turbine power shaft. The paddle wheel blade configuration is interposed between the pressurized fluid inlet and outlet ports for efficient response to the pressurized fluid moving therebetween. Directional fans mounted about the rotating shaft maintain the fluid flow through the turbine so as to assure an optimum power as offered by the rotating turbine shaft. A home power generation system utilizing the turbine is also disclosed herein.
U.S. Pat. No. 4,776,762
Inventor: Leo W. Blowers
Issued: Oct. 11, 1988
[0019] A power conversion turbine for actuation by fluid in motion such as, for example, the wind, with a body supported to rotate about a central axis and carrying a plurality of vanes spaced from said axis and being movable about respective vane axes parallel to said central axis and which vanes are circumferentially spaced from each other and dimensioned such that, when said vanes are in a first closed position they collectively form a substantially unbroken cylindrical surface and are selectively movable from said first position to a fully open second position and said vanes including interconnecting means causing selected ones of said vanes to close as one or more opposing vanes are caused to move from the first to the second position by reason of passage of fluid and means integrally connected with said interconnecting means for infinitely varying the degree of opening of the vanes between fully closed and fully open positions. An auxiliary strip may be provided along the full length of the inner surface of each vane near the leading edge to facilitate and accelerate the initial opening movement of the vanes.
U.S. Pat. No. 5,051,059
Inventor: T. Peter Rademacher
Issued: Sep. 24, 1991
[0020] A hinged vane rotor generating power from rivers, streams, tides or wind. A cylindrical drum is supported sideways in a current by axles at the ends connected to pulleys which are in turn, connected to a generator(s), mill wheel, pump or other working device. The rotor is turned by a series of hinged vanes, each one opening to catch the current on one side of the drum and closing to avoid the current on the other side of the drum. A fluid directing component is incorporated to increase current against one side of the drum and reduce it against the other side.
U.S. Pat. No. 6,006,518
Inventor: Jeffrey B. Geary
Issued: Dec. 28, 1999
[0021] An ocean current energy converter is disclosed which, by positioning upon an ocean floor, harnesses and converts energy stemming from wave, tide, and current propagation into useful electrical power. The ocean current energy converter comprises a pair of support legs which are secured to a rotating canister which comprises a plurality of fins disposed about an outer periphery of said rotating canister. Wave motion acting upon the fins of the rotating canister causes said canister to rotate, thus driving a power generating source contained therein, and producing electrical energy.
U.S. Pat. No. 6,499,939
Inventor: Eric E. Downing
Issued: Dec. 31, 2002
[0022] The present invention 10 discloses a wheel-like member 30 consisting of a central circular body member 18 having a plurality of spokes 22 radiating from its outside perimeter that attach to the inside perimeter of an outer circular body member 24 . On the outside perimeter of the outer circular body member a plurality of hinges 26 with paddles 16 are attached thereto that can only open to a pre-determined angle “A” from the wheel 30 that ensures water current 14 is caught by the paddles on only one side of the wheel which causes the wheel to rotate in only one direction. The kinetic energy stored in the wheel 30 while rotating is harnessed through a drive shaft 34 connected to the central circular body member 18 that connects to a generator 36 placed perpendicular to the central circular body member 18 . To keep the generator 36 and drive shaft 34 in place a plurality of support members 40 , with cross-member support couplers 48 are disposed into the bed 42 of the river or ocean that the device 10 is being used in.
U.S. Pat. No. 7,090,553
Inventor: Donald S. Seiford, Sr.
Issued: Aug. 15, 2006
[0023] A paddle wheel propulsion system includes a paddle wheel mounted for rotation about its horizontal axis for propelling a vessel, and for unlimited rotation about a vertical axis perpendicular to its horizontal axis for steering the vessel. The paddle wheel is also supported for limited vertical movement relative to the vessel. Reversible power drive is provided for independently controlling movement of the paddle wheel about its vertical and horizontal axes and for elevating and lowering the paddle wheel. Improved paddles are concave on both sides to provide maximum efficiency in both direction of rotation about the horizontal axis.
Russian Patent Number: RU201620
Inventor: Viktor Bojarshinov
Issued: Jul. 15, 1994
[0024] A working wheel with blades and their rotary mechanism is mounted on a shaft. The mechanism is made in the form of a system of movable and stationary relative to their axes gears with gear ratio 2/1. Gears movable relative to their axes are mounted on the axes of the blades, the stationary gears on the wheel axle. The movable gears are interconnected around the periphery and connected to the stationary ones along the radius by chain gears.
International Publication Application Number: WO 2004/085841
Inventor: Carlos Aristides Castaneda Mungi
Issued: Oct. 7, 2004
[0025] The hydraulic generator consists of a rotor and multiple paddles with synchronized rotation between rotor and paddles, has been conceived with the purpose of being able to obtain the larger percentage of the water energy, taking advantage of the water energy, taking advantage of the horizontal drive of this, which is transmitted by the paddles to the rotor, by a leverage effect through the pinions or sprockets of the rotor. The special design of this invention shows the synchronized rotation between rotor and paddles, which is achieved by means of pinions with chain belts or synchronous pulley with synchronous band in a relation of 1 to 2 in the diameter of the pinions or pulley of the rotor and paddles respectively. This invention is classified within the energy generator of motion to be applied in electrical generators, water pumps, moll and all equipment that with require of an external source of this type.
[0026] While these water and wind driven systems may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention.
SUMMARY OF THE PRESENT INVENTION
[0027] A primary object of the present invention is to provide a wind or water powered wheel having pairs of radially positioned arms with each having a shaft with a pair of fins pivotally attached thereto. Another object is to provide a wind or water powered wheel whereby the fins are independently movable.
[0028] An additional object is to provide a wind or water powered wheel whereby one fin is driven in a vertical plane while the bottom fin is driven in a horizontal plane within a channel.
[0029] Yet an additional object is to provide a wind or water powered wheel whereby said channel provides means for encapsulating a lead bearing fixedly attached to each fin allowing the fin to transverse around a centralized pivot point.
[0030] Still yet an additional object is to provide a wind or water powered wheel whereby upon rotation about the channel the encapsulated lead bearing reaches a transfer switch that forces the lead bearing out of the channel while leading a trailing bearing or (free bearing) fixedly attached to the opposing end of the fin into the channel.
[0031] An additional object is to provide a wind or water powered wheel whereby optimal fin position is obtained to provide maximum power to the main shaft and thus improved generation of power.
[0032] A further object is to provide a wind or water powered wheel that is simple and easy to use.
[0033] A still further object is to provide wind or water powered wheel that is economical in cost to manufacture and operate.
[0034] Additional objects of the present invention will appear as the description proceeds.
[0035] The present invention overcomes the shortcomings of the prior art by providing A turbine powered by a moving fluid such as air or water has a pair of oppositely disposed wheels; a main shaft connecting the wheels as an axle, such that each of the wheels has an inboard side and an outboard side; a circular channel in each of the inboard sides of the pair of wheels; a pair of oppositely disposed arms connected at one end, at right angles, to the main shaft; a pivot bearing connected to a distal end of each of the arms; a fin shaft rotatably connected through each pivot bearing with a pair of distal ends disposed on opposite sides of each pivot bearing, the fin shaft generally parallel to the main shaft; a fin rotatably affixed at the middle of one side to each fin shaft distal end, the fin having a distal free side and each fin being independently rotatable; a pair of roller bearings extending from opposing ends of the distal free side of the fins, the roller bearings sized to fit within the circular channels and oriented such that the fins traverse around the pivot bearing and the pair of roller bearings alternately enter and revolve through the circular channels in the wheels, with the roller bearing in the channel being a lead bearing and the roller bearing outside the channel being a free bearing; and a transfer switch in each of the channels which forces the lead bearing out of the channel while urging the free bearing into the channel.
[0036] The foregoing and other objectives and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings, which forms a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views.
[0037] The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0038] In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings.
[0039] FIG. 1 is an illustrative view of the present invention's use.
[0040] FIG. 2 is a front perspective view of the present invention in use with a fluid.
[0041] FIG. 3 is a front perspective view of the present invention in use with wind.
[0042] FIG. 4 is an exploded view of the present invention.
[0043] FIG. 5 is a detail view of the present invention.
[0044] FIG. 6 is a side view of the present invention operating in water.
[0045] FIG. 7 is a side view of the present invention operating in the wind.
[0046] FIG. 8 is a detailed progression view of the present invention's transfer switch.
[0047] FIG. 9 is a front view of an additional element of the present invention.
[0048] FIG. 10 is a front view of an additional element of the present invention.
[0049] FIG. 11 is a side view of the present invention having additional arms.
[0050] FIG. 12 is a detailed view of an additional element of the present invention.
DESCRIPTION OF THE REFERENCED NUMERALS
[0051] Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Water and Wind Turbine of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.
10 Water and Wind Turbine of the present invention 12 watercraft 14 stationary plate 16 fin 18 main central shaft 20 arm 22 power transfer 24 pivot bearing 26 channel 28 roller bearing 29 fluid movement 30 wind 32 water 34 lead roller bearing 36 free trailer bearing 38 fin shaft 40 generator 42 inboard side of 14 44 outboard side of 14 46 pivot transfer switch 48 rotation of 16 50 excessive force 52 restrainer 54 pivot point of 16
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0076] The following discussion describes in detail one embodiment of the invention (and several variations of that embodiment). This discussion should not be construed, however, as limiting the invention to those particular embodiments; practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims.
[0077] FIG. 1 is an illustrative view of the present invention 10 in use. Shown is the present invention 10 being a pair of spaced apart stationary plates 14 having a plurality of fins 16 disposed therebetween angularly disposed into optimum positioning for maximum driving and power production therefrom. Additionally, the present invention 10 may be utilized as an air driven turbine or as a water 31 driven wheel as depicted. In a reversed and powered scenario the present invention 10 may also be utilized as a propulsion means for watercraft 12 .
[0078] FIG. 2 is a front perspective view of the present invention 10 in use with a fluid. The present invention 10 is a turbine powered by a moving fluid 29 , such as wind or water, turning a central shaft 18 having pairs of radially positioned arms 20 with each having a fin shaft 38 with a pair of fins 16 pivotally attached thereto. The fins 16 are independently movable one from the other whereby one is driven in a vertical plane while the opposed fin 16 is driven in a horizontal plane. Power transfer 22 is accomplished between the central shaft 18 and a generator 40 Additionally the present invention 10 may be coupled to a motor or source of torque to be manually rotated and driven in a manner that can be utilized in powering small watercraft.
[0079] FIG. 3 is a front perspective view of the present invention 10 in use with wind 30 . The present invention is a moving fluid powered turbine 10 having an pivot bearing 24 in rotative communication with the shafts 38 of a set of fins 16 attached to arms 20 radiating from a central, main shaft, 18 serving as an axle and disposed between two stationary plates 14 , each fin 16 has a roller bearing 28 attached to the two outer corners. While one said bearing 28 runs along a circular channel 26 of a smaller diameter than that of the arm 20 , the angle that each fin 16 rotates is controlled in order to transfer maximum energy to the power transfer 22 of the main shaft 18 . Shown are the fins 16 being driven by the wind 30 . The stationary plates 14 includes an inboard side 42 with the central shaft projecting perpendicularly therefrom and an outboard side 44 .
[0080] FIG. 4 is an exploded view of the present invention 10 . The present invention 10 has a main shaft 18 with a plurality of support arms projecting perpendicularly therefrom with the distal end of each having a pivot bearing 24 rotatively connected to a pair of rectangular fins 16 , having one on each side of the arm, which rotates. Each fin 16 has a roller bearing 28 attached its two outer corners. While one said bearing 28 runs along a channel in a circular track of a smaller diameter than that of the arm, the angle that each fin 16 rotates is controlled, in order to transfer maximum energy to the main shaft 18 .
[0081] FIG. 5 is a detail view of the present invention 10 . Shown is a detail view of the fin 16 , arm 20 and roller bearings 28 of the present invention 10 . This wind or water powered wheel provides pairs of radially positioned arms 20 with each having a shaft with a pair of fins 16 pivotally attached thereto via a pivot bearing 24 in a pivot bearing housing 25 . The fins 16 are independently movable from the other whereby one is driven in a vertical plane while the opposed fin 16 is driven in a horizontal plane. Additionally shown is the present invention having a pressure release gate 32 whereby under the incident of extreme weather, release is caused, to permit flow that otherwise would destroy the fin if opposed.
[0082] FIG. 6 is a side view of the present invention operating in water 31 . The present invention 10 has a central shaft 18 with perpendicularly extending arm 20 having a pivot bearing 24 that supports the rectangular fins 16 having one fin 16 on each side of the arm 20 , which rotates. Each fin 16 has a roller bearing 28 attached to the two outer corners. While one runs along a circular channel 26 , which is of a smaller diameter than that of the arm 20 , dictates the angle of each fin 16 as it rotates 16 to transfer maximum energy to the main shaft 18 . A pivot switch 46 alternates the positions of the roller bearings 28 so the lead bearing 34 traveling within the channel 26 becomes the free trailing bearing 36 .
[0083] FIG. 7 is a side view of the present invention 10 operating in the wind 30 . The main central shaft 18 is slightly offset from the center of the stationary plates 14 and a pivot transfer switch 46 forces the lead roller bearing 34 from the channel 26 and transfers the free trailing bearing 36 into the lead roller bearing 34 . A pressure release gate 32 integral with each fin 16 responds to excessive force 50 by opening to relieve the pressure and prevent damage to the apparatus. Also shown is the restrainer 52 .
[0084] FIG. 8 is a detailed progression view of the present invention's 10 pivot transfer switch 46 . Depicted below is the transfer switch 46 with a pivot point 54 that forces the lead roller bearing 34 out of channel 26 and thus becoming a free trailer bearing 36 . Upon continued rotation the pivot transfer switch 46 pivots upon an anchor point that provides means for the trailing or free bearing 36 to enter the channel 26 and thus becoming the lead bearing 34 .
[0085] FIG. 9 is a front view of an additional element of the present invention 10 . The wind/water turbine of the present invention 10 provides a pair of spaced apart stationary plates 14 with guide channels 26 having at least one pair of radially positioned fins 16 situated approximately 90 degrees one from the other. Each pair of fins 16 has roller bearings 28 positioned on its top and bottom distal ends and are pivotally fixed to an arm 20 connecting to a central shaft 18 in communication with a power conversion generator 40 that converts the mechanical energy from wind or water that pushes the fins 16 into electrical current. The fins 16 rotate within pivot bearings 24 to optimize harvesting of potential energy while reducing drag.
[0086] FIG. 10 is a front view of an additional element of the present invention 10 . The present invention 10 may be expanded and ganged with a plurality of fins 16 and arms 20 operating on a common main shaft 18 and generator 40 as the roller bearings 28 travel through the channels 26 of the stationary plates 14 .
[0087] FIG. 11 is a side view of the present invention 10 having additional arms 20 . Shown is the present invention 10 being utilized as a water driven turbine whereby the disposition of the fins 16 are switched from top to bottom in the channel 26 . The changed angular juxtaposition allows the fins 16 of stationary plates 14 to be placed in maximum positioning for harnessing said water's flow and transferring the potential energy from the main shaft 18 to the generator. Additionally the present invention 10 may be operated in flows directed in either direction allowing it to function in reciprocating currents.
[0088] FIG. 12 is a detailed view of an additional element of the present invention 10 . Shown is the present invention 10 having an additional element being a retaining rail 52 that is utilized in guiding the bearings 28 as they pass through the pivot transfer switch 46 during reverse rotation.
[0089] 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 methods differing from the type described above.
[0090] While certain novel features of this invention 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.
[0091] 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. | A power generation system that provides means for a wind or water powered wheel having pairs of radially positioned arms each having a shaft with a pair of fins pivotally attached thereto and where the independently rotating fins or paddles allow for increased power generation and reduced drag. | 8 |
This is a continuation of application Ser. No. 784,595, filed Apr. 4, 1977 which is a Cont. of Ser. No. 640,341 filed Dec. 12, 1975 both abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of fibrous sheet materials such as paper, cardboard, nonwoven materials and more specifically it relates to the method of their manufacture.
Known in the art is an aerodynamic method of manufacturing fibrous materials consisting in that the fibrous raw material with an absolute moisture content of 5 to 100% and over of the weight of absolutely dry fibres which amounts to 95-50% and less in terms of concentration of fibres in the mass is preliminarily dispersed into individual fibres which are introduced into a stream of air for producing an air-material mixture in the form a directional flow delivered onto the moving screen of a moulding chamber.
Then the fibres are distributed over the screen by mechanical atomization of the mixture. The fibrous material is moulded on the moving screen by settling the fibres from the air-material mixture under the effect of pressure difference above and under the screen.
After producing a uniform layer of the fibrous material on the moving screen, said layer is mechanically compacted. Then the compacted material is dried and finished.
Owing to a high concentration of the source fibrous material (95-50%) the known method fails to generate the required amount of stream for dispersing the compacted fibre clots in the process of conveying the air-material mixture into the moulding chamber. Hence, the known method does not ensure a high degree of dispersion and distribution of fibres in the stream. This disadvantage in turn impairs the quality of the finished fibrous material which is characterized by an insufficiently uniform distribution of fibres and, as a consequence, by a low tensile strength. This also leads to a low speed of material moulding, a low output of the production equipment and a limited number of manufactured products. Thus, the known method can be utilized for manufacturing cardboard only.
There have been attempts made to eliminate the aforesaid disadvantages. A method has been envolved which has raised the uniformity of distribution fibres in the manufactured sheet material and increased its tensile strength. The source material in this method has been wood pulp subjected to mechanical and thermal treatment at 100° C. and higher to a moisture content of 30% and above (concentration of fibres in the mass being 70% and less).
The mass with the above-specified moisture content is distributed in a stream of gas thus producing an air-material mixture which is then directed into a moulding chamber and moulded similarly to the method described above.
In our opinion, the thermal treatment of the fibrous raw material in the above-described method equalizes the variations in the wetness of fibres in the moulding chamber which has a positive effect on the more uniform distribution of fibres in the chamber and in the finished fibrous sheet material. This in turn improves somewhat the tensile strength of the material.
However, in view of a relatively low wetness of the fibrous raw material this method is not quite efficient for producing fibrous materials with a high tensile strength and obtaining a high moulding speed.
Besides, both methods described above are rather complicated since they involve a number of individual successive operations such as dispersing the fibres, forming an air-material mixture and distributing the fibres in said mixture.
SUMMARY OF THE INVENTION
An object of the present invention lies in providing a method of manufacturing a fibrous sheet material which would ensure a high moulding speed and a wide number of finished materials characterized by a high tensile strength and a low cost.
This object is accomplished by providing a method of manufacturing a fibrous sheet material from a moist fibrous raw material by dispersing it, forming an air-material mixture flowing in a stream into a moulding chamber, distributing the fibres in the chamber and moulding the sheet material on the moving screen of the moulding chamber by settling fibres from the air-material mixture at a pressure difference above and under the screen followed by mechanical compaction, drying and finishing wherein, according to the invention, the moist fibrous raw material is constituted by a suspension of the fibrous material with a concentration of fibres varying from 5 to 30 wt.-%, the suspension is heated before dispersion to 102°-145° C. under a pressure of 1.1-4.0 atm abs and delivered into a moulding chamber where pressure in the stream is sharply reduced in the course of 10 -1 -10 -3 s down to 0.8-1.0 atm abs which ensures dispersion of the fibres in the produced steam-air medium with simultaneous formation of an air-material mixture and uniform distribution of fibres in said mixture.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The essence of the invention lies in the following.
The use of the suspension of a fibrous material with the concentration of fibres varying from 5 to 30% ensures such an amount of moisture in the moulded sheet material which is necessary for creating hydrogen bonds in the process of its drying, said bonds raising the tensile strength of the fibrous material.
The attainment of high strength of the finished fibrous material makes it possible to dispense with the use of binders, both synthetic and certain natural binders such as casein, starch, etc. which reduces the cost of the finished products.
The heating of the suspension of the fibrous material with the concentration of fibres varying from 5 to 30 wt.-% to 102°-145° C. allows building up a pressure of 1.1-4.0 atm abs in said suspension. This pressure is sufficient for conveying the fibrous mass towards the moulding chamber.
A sharp reduction of pressure from 1.1-4.0 atm abs to 0.8-1.0 atm abs increases the active surface of the fibres thereby increasing the moulding speed of the material.
This is accompanied by a sharp expansion of steam in the fibrous suspension contained in the moulding chamber; this causes dispersion of the suspension clots into individual fibres and their uniform distribution in the moulding chamber with simultaneous formation of an air-material mixture.
As a result, it has become possible to combine such operations as dispersion of the fibrous material into individual fibres, formation of an air-material mixture and uniform distribution of fibres in the chamber.
The combination of these operations at the material moulding stage simplifies considerably the manufacture of the fibrous material and ensures efficient control of the manufacturing operations.
To make the essence of the invention more apparent it will now be described by way of examples.
EXAMPLE 1
For manufacturing cardboard, the fibrous suspension of bleached sulphite cellulose with a concentration of 5% and a freeness of 90° according to Schopper-Riegler has been heated by steam at a temperature of 142° C. under a pressure of 4 atm abs to the state of equilibrium of moisture content between the fibrous suspension and steam in the closed volume of the heating chamber.
The heated fibrous suspension has been delivered in a stream of air and steam into a moulding chamber and the steam pressure has been sharply reduced from 4 atm abs to 1 atm abs which led to dispersion of the fibrous suspension in the steam-air medium, formation of an air-material mixture and uniform distribution of fibres in said mixture. Then the fibres have been settled on a moving moulding screen from the steam-air mixture of bleached sulphite cellulose under a pressure difference of 920 mm H 2 O created above and under the moving screen. The moulded moist sheet of cardboard has been dried through contact with a heated surface. The produced cardboard has been characterized by the following physical and mechanical properties: mass per 1 m 2 -240 g; breaking length-3500 m; density-0.63 g/cm 3 ;
EXAMPLE 2
For manufacturing cardboard, the fibrous suspension of waste paper with a fibre concentration of 10% and a freeness of 45° according to Schopper-Riegler has been heated with steam at 120° under a pressure of 2 atm abs to the state of equilibrium of moisture content between the fibrous suspension and steam in the closed volume of the heating chamber. The heated fibrous suspension has been delivered also in a an air-steam stream into a moulding chamber and the steam pressure has been sharply reduced from 2 atm abs to 1 atm abs. The following operations have been the same as in Example 1. The produced carboard has had the following physical and mechanical properties: mass per 1 m 2 -170 g; breaking length-2150 m, density-0.50 g/cm 3 .
EXAMPLE 3
For manufacturing wrapping paper, the fibrous suspension of brown wood pulp with a fibre concentration of 18% and a freeness of 65° according to Schopper-Riegler has been heated by steam at 130° C. under a pressure of 2.8 atm abs to the state of equilibrium of moisture content between the fibrous suspension and steam in the closed volume of the heating chamber. The heated fibrous suspension has been delivered in a stream of air and steam into a moulding chamber and the steam pressure has been sharply reduced from 2.8 atm abs to 1 atm abs. The following operations have been the same as in Example 1. The physical and mechanical properties of the produced wrapping paper have been as follows: mass per 1 m 2 -70 g; breaking length-3000 m; density-0.48 g/cm 3 .
EXAMPLE 4
For manufacturing cardboard, the fibrous suspension of bleached sulphite cellulose with a fibre concentration of 30% and a freeness of 90° according to Schopper-Riegler has been heated by steam at 142° C. under a pressure of 4 atm abs to the state of equilibrium of moisture content between the fibrous suspension and steam in the closed volume of the heating chamber. The heated fibrous suspension has been delivered also in a steam of air and steam into a moulding chamber and the steam pressure has been sharply reduced from 4 atm abs to 1 atm abs. The following operations have been similar to those in Example 1. The physical and mechanical properties of the produced cardboard have been as follows: mass per 1 m 2 -230 g; breaking length-2800 m; density-0.65 g/cm 3 .
The above-described examples of manufacturing fibrous sheet materials from various raw materials show that the finished product has a sufficiently high tensile strength which allows the manufacturing process to be carried out at speeds exceeding 100 m/min. On the other hand, the manufacture of fibrous materials with this strenth makes it possible to dispense with the use of costly binders which cuts down considerably the price cost of the finished product.
The use of various wood fibres for the source material widens considerably the number of types of finished products. | A distinguishing feature of the method lies in that the moist fibrous raw material is constituted by a suspension of a fibrous material with a fibre concentration of 5-30 wt. %; said suspension is heated before dispersion to 102°-145° under a pressure of 1.1-4.0 atm abs and fed in the form of a stream into a moulding chamber where pressure in the stream is sharply reduced to 0.8-1.0 atm abs in the course of 10 -1 -10 -3 seconds. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a method of verifying the identity of a pipeline at one location as being the same as a pipeline at another location.
In pipeline work, identification of pipelines already in place for a period of time is increasingly becoming a more difficult problem despite the use of color codings, maps, etc. In large part, this increase in difficulty is due to the ever increasing number of lines being laid, more activity on the lines, and more emphasis being placed on environmental concerns. For example, when a worker digs down into a pipeline right of way for natural gas pipelines, he is often confronted with several pipelines. How is he to be sure which one of the several lines is the one which has been purged of explosive gas before he cuts into it with his cutting torch. This uncertainty of identification exists even of pipelines above ground where tracing would seem very easy. But, for example, where the location of work to be carried on a pipeline is miles distant from its source or is in a pipe rack containing several lines, such tracing becomes increasingly difficult. The uncertainty of having the wrong pipe is a very real factor to the worker, or it should be, for there have been many incidents wherein serious injuries and fatalities have occurred.
Several pipeline location devices have been tried but due to pipeline crossings and turnings and due to the presence of older and newer pipelines in the same vicinity, often known but also often unknown, these location devices have not proven as satisfactory as one would desire.
Hence it would be highly advantageous to have a method of positive pipeline identification. The present invention achieves this.
SUMMARY OF THE INVENTION
The present invention is a method for verifying that the identity of a pipeline at a first location is the same as the pipeline located at a second location. This method comprises three steps. First, a strain gage is attached to the pipeline at the first location. Secondly, pressure in the pipeline is varied by pressure varying means at the second location. Thirdly, the strain gage is observed to see if its output corresponds in time and magnitude to the pressure variations applied at the second location.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of the locations and equipment involved in the method of this invention.
FIG. 2 is a reproduction of the strain gage strip recorder read-out for Example II.
DETAILED DESCRIPTION OF THE INVENTION
A clearer understanding of this invention may be obtained by reference to FIG. 1 wherein a pipeline 10 at one location is desired to be positively identified as being the same as a pipeline 12 at another location. A place on pipeline 10 is prepared for receiving a strain gage. Strain gage 14 is affixed, preferably welded to save much time, to pipe 10 in a manner so as to measure any change in strain in said pipe 10. A portable strain read out meter 16 is electrically connected to strain gage 14 by wires 18. A portable strip chart recorder 20 is connected to strain read out meter 16 by wires 22.
The pressure in pipe 12 at the other location is then varied at a specified time in any one of the multitude of pressure change patterns by pressure changing means 24. Pressure changing means can be a valve, a pump or any other device suitable for changing pressure in a pipeline.
EXAMPLE I
A four-inch diameter, schedule 40 underground pipeline was located underground beneath and cutting across a drainage ditch at a site near the sewage disposal plant in the city of Clute, Texas. This pipeline needed to be cut into and worked on in order to bury it deeper as the drainage ditch was to be enlarged and deepened. In the area around this drainage ditch site, there were known to be several other pipelines. It was thought that the pipeline to be worked on was about a 14-mile pipeline carrying a flammable liquid between two separated facilities of The Dow Chemical Company. The drainage ditch pipeline site in Clute was about midway between the two Dow sites. At one end of the 14-mile pipeline connecting the two Dow sites was a compressor used for pumping the flammable liquid through that pipeline which was capable of changing the pressure in that pipeline.
Although the identity of the pipeline crossing the drainage ditch was thought to be the same as the pipeline connecting the two Dow facilities, it was desired to positively identify the pipeline crossing under the drainage ditch as being the same as the pipeline connecting the two Dow facilities.
To positively identify pipeline at the drainage ditch as being the same as the pipeline connecting the two Dow facilities, the following equipment and procedure were used.
Equipment
1. Portable strain indicator, Model P340A from Vishay Instruments of Raleigh, North Carolina.
2. Portable strip chart recorder, Model 4201 from Soltec Corporation of Sun Valley, California.
3. Portable strain gage welder system including weldable strain gages from Ailtech of City of Industry, California.
4. Portable hand grinder, Model 280 from Dremel, available from local hobby shops or hardware stores.
5. Portable 115 volt power generator, Model ER400, from Honda at local Honda distributor.
Procedure
1. Using the portable 115 volt generator as a power source, the hand grinder was used to clean a section of about 1 inch by 3 inches off the surface of the pipeline located at the drainage ditch site which pipeline had previously had the dirt removed from it.
2. The weldable strain gage was welded to the cleaned surface of the drainage ditch pipeline using the strain gage welder system and the portable 115 volt generator.
3. The strain gage was connected to the portable strain indicator which in turn was connected to the portable strip chart recorder at the drainage ditch pipeline site.
4. Via radio from the drainage ditch pipeline site, an operator at one of the Dow facilities was instructed to lower and then raise the pressure in the line connecting the two Dow facilities by 50 pounds per square inch using a compressor located at that facility. The 50 psi pressure changes were derived using the following criteria: a strain change of 20 microinches per inch would clearly show up on the drainage ditch pipeline strain gage and accompanying equipment and a pressure change of 50 psi was calculated to produce this 20 microinch/inch strain according to the following rule of thumb formula: ##EQU1##
5. The operator at the Dow location lowered the pressure of the pipeline connecting the two Dow facilities and a strain change of 16 microinches/inch was detected on the pipeline at the drainage ditch site.
The Dow operator then raised the pressure by 50 psi in the pipeline connecting the two Dow facilities and the strain gage equipment attached to the drainage ditch pipeline showed an increase of 16 microinches/inch.
This correspondence of strain change in the pipeline at the drainage ditch site to the 50 psi pressure changes in the pipeline connecting the two Dow facilities positively identified the two as being the same pipeline. Hence, when the pipeline connecting the two Dow facilities was subsequently emptied and purged from the Dow facility sites, the workmen at the drainage ditch pipeline site could be assured that they were going to cut into a pipeline with a cutting torch which was indeed purged instead of only thought to be purged.
The above set-forth procedure for positively identifying the drainage ditch pipeline took approximately 30 minutes. The use of a normal nonweldable strain gage would have required about two hours or more. Hence, weldable strain gages are greatly preferred.
EXAMPLE II
A short piece (about 60 feet long) of 4-inch diameter, schedule 40 pipe was hydro-tested for strain gage changes induced by pressure changes in the water in the pipe. The same equipment and procedure as that used in Example I were used except that a valve was used to release the pressure in the pipe and was visually identifiable as being on the pipe, and the pipe was above ground. Pressure drops of 50 psi were induced in the pipe at four separate times. FIG. 2 is a reproduction of the strip chart strain recordings corresponding to these four pressure reductions. In FIG. 2, graph segments identified as a, b, c and d show that the four pressure reductions produced a corresponding negative strain reduction of approximately 15 microinch per inch.
Using this equipment and procedure, it was discovered that pressure changes as small as 50 pounds per square inch can give unmistakable corresponding changes on the strain gage recorder. | Identity of pipeline at a first location as being the same pipeline at a second location, at which the pipeline pressure can be varied, is achieved by attaching a strain gage to the pipeline at the first location, varying the pressure in the pipeline at the second location, and observing the strain gage to see if it varies correspondingly to the pressure changes. | 6 |
This application is a continuation of Ser. No. 303,330 filed Nov. 3, 1972, now abandoned.
FIELD OF THE INVENTION
The invention relates to modifiers effective as molecular weight regulators in suspension polymerization systems. In another aspect, the invention relates to a process of suspension polymerization.
BACKGROUND OF THE INVENTION
Mercaptans commonly are employed in suspension polymerization systems to act as molecular weight regulators or modifiers. While effective, these have, at times, exhibited some objectionable characteristics such as residual mercaptan odor in the polymeric product. Possible volatilization of lower molecular weight species may be objectionable in some environments, either due to the odor, or to corrosion or discoloration of metal where the mercaptan modified polymer is in contact with a metal in the further presence of moisture.
It would be desirable to be able to produce polymeric products that exhibit satisfactory physical properties, but employing molecular weight modifiers that either would be free of objectionable residual odor, or would have minimal odor of other than a sulfur derived type, and for many applications modified rubbers not containing sulfur would be highly desired.
OBJECTS OF THE INVENTION
It is an object of the invention to provide new classes of modifiers for suspension polymerization systems.
Other objects, advantages and features of our invention will be apparent to those skilled in the art from the following discussion.
BRIEF SUMMARY OF THE INVENTION
Iodine, in the form of the element or as organic iodide, is effective as a molecular weight modifier or regulator in suspension polymerization systems.
DETAILED DESCRIPTION OF THE INVENTION
The invention lies in the employment of iodine, either as elemental iodine or as organic iodide, as a molecular weight regulator or modifier, particularly in suspension polymerization systems. These modifiers are effective and convenient to use.
The invention encompasses the use of our modifiers in conjunction with other modifiers, including a mixed mercaptan modifier-iodine modifier system. Of course, where mutual interaction might occur between the iodine modifier and some other modifier, which would preclude effectiveness, such would not be suitable.
IODINE MODIFIERS
In referring to "iodine modifiers" or "iodine compound" in our disclosure, we include both elemental iodine and the organic iodides for convenience in discussion without needless repetition. Any of the organic iodides possessing the requisite reactivity can be used in the context of our invention. So long as the iodine modifier exhibits adequate solubility in the monomers and solvent used in the suspension polymerization system, and so long as the organic structure did not become so great as to, in effect, overshadow the presence of iodine in the molecule and reduce effectiveness as modifier, then the organic iodine modifier should be satisfactory, and the particular number of carbon atoms per molecule is not a specific operable limit.
The organic iodide modifiers presently suggested for most purposes as modifiers contain up to 20 carbon atoms per molecule, and from one to several iodine atoms per molecule. More than one iodine atom can be present on an individual carbon atom within a molecule. The organic portion of the structure can be saturated or unsaturated aliphatic, or cycloaliphatic or aromatic, such as alkyl, alkenyl, cycloalkyl, cycloalkenyl, or aryl, or any combination thereof, such as alkaryl, aralkyl, and the like. The organic iodine compounds encompass a wide range of molecular structures and variations in reactivity of the individual carbon-iodine bonds, which permit the practitioner of our invention to select modifiers of the desired degree of solubility and activity, governed by the requirements of the individual polymerization system for which a modifier is desired.
The following species are provided for illustration, and not intended to be necessarily limiting or all encompassing: iodine itself, methyl iodide, carbon tetraiodide, ethyl iodide, diiodomethane, hexaiodoethane, 1,1-diiodopropane, 2-iodooctane, 2,7-diiodo-10-methylpentadecane, 1-iodoeicosane, iodocyclohexane, iodobenzene, 1,4-diiodobenzene, benzyl iodide, 4-methyliodobenzene, allyl iodide, and iodine-substituted naphthalene, anthracene, and the like. Of course, noninterfering substituents, e.g., remotely located methyl groups, are permissable in any of the modifiers.
The iodine modifiers should be added to the suspension polymerization system in amounts sufficient for the effect desired and the degree of modification necessary depending on the monomers, polymerization temperatures, and other conditions. A typically employed range for iodine, free or chemically combined, for most suspension systems would be an amount equal to about 0.01 to 2, preferably about 0.4 to 1.5, weight per cent based on the weight of monomers charged. These values are exclusive of any rubbery or resinous component, if used, in the suspension polymerization process.
MONOMERS
Any monomer or monomer combination polymerizable in a suspension polymerization system can be utilized in the practice of our invention. Our invention lies in the novel modifiers and process of employing the novel modifiers, not in the particular suspension process or monomers, since these are well known in the art. In general, any suspension polymerization system for polymerization of monomers polymerizable in a suspension polymerization system and wherein molecular weight modifiers are employed, particularly such as the mercaptan molecular weight modifiers, can enjoy the application of our invention.
Polymers prepared by suspension polymerization systems range from various resinous types such as polystyrene, poly(methyl methacrylate), styrene/acrylonitrile copolymers, to elastomeric or rubbery types such as butadiene/styrene copolymers, or mixed polymers of the butadiene/acrylonitrile type, and the like. Monomeric starting materials may be employed, or suspensions can be made of rubbery polymers such as polybutadiene or butadiene/styrene copolymers, dissolved in monomers such as styrene or styrene and acrylonitrile, and the rubber-in-monomer solution placed in a suspension system for further co- and graft polymerization of the polymerizable monomer onto the polymer.
Monomers employed as monomeric materials in suspension polymerization systems include polymerizable monovinyl-substituted aromatic compounds and other polymerizable monomers such as the nitriles, esters of acrylic acids, or of alkacrylic acids, and vinyl esters. Such suspension system-polymerizable monomers most commonly include the monovinyl-substituted aromatic compounds of 8 to 20 carbon atoms per molecule, vinyl nitriles of 8 to 20 carbon atoms per molecule, alpha, beta-unsaturated nitriles, esters of acrylic acid, and vinyl esters, of up to 20 carbon atoms per molecule, and the like.
While polymerizable monomers such as the conjugated dienes are not employed as monomers in our suspension polymerization sytem, these monomers commonly are employed in polymerization systems, such as solution polymerization with organoalkali metal initiators, to prepare polymers of the conjugated dienes such as polybutadiene, butadiene/styrene copolymers, mixed polymers such as butadiene/acrylonitrile type, and the like, and these polymers then are dissolved in other polymerizable monomers such as described above for graft and copolymerization in the suspension polymerization system. Such conjugated dienes include any of the polymerizable conjugated dienes, for commercial availability from 4 to 12 carbon atoms per molecule in most instances, such as 1,3-butadiene, isoprene, piperylene, 2,4-dimethyl-1,3-butadiene, 1,3-octadiene, 4,5-diethyl-1,3-octadiene, and the like.
Examples of monomers described above include styrene, various alkyl substituted styrenes such as ethylstyrene, acrylonitrile, methacrylonitrile, methyl acrylate, vinyl acetate, vinyl butyrate, 4-vinylbiphenyl, 2-vinylnaphthalene, and various combination systems or mixtures thereof such as butadiene/styrene, styrene/acrylonitrile, butadiene/styrene/acrylonitrile, and the like.
INITIATOR
Although the suspension polymerization reaction may proceed thermally, it is preferable to incorporate into the polymerization system a free-radical generating initiator. Initiators useful in the context of this invention include the monomer-soluble organic peroxides, such as di-t-butyl peroxide, benzoyl peroxide, lauroyl peroxide, toluyl peroxide, t-butyl peracetate, t-butyl perbenzoate, dicumyl peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexyne-3, t-butyl hydroperoxide, cumene hydroperoxide, p-menthane hydroperoxide, cyclopentane hydroperoxide, diisopropylbenzene hydroperoxide, pinene hydroperoxide, 2,5-dimethylhexane-2,5-dihydroperoxide, and the like, and mixtures thereof; as well as any of the monomer-soluble azo initiators useful in suspension polymerization systems such as 2,2'-azobis(2-methylpropionitrile), 2,2'-azobis(2-methylvaleronitrile), and the like, and mixtures. The quantity of initiator employed usually ranges from about 0.005 to 1 weight percent of the total weight of monomers charged, though this may be varied as desired dependent on the reactants, temperatures, and the like.
SUSPENSION POLYMERIZATION
Suspension polymerization refers to a system in which monomers relatively insoluble in water are suspended as liquid droplets using a suspending agent so as to maintain the suspension, and the resultant polymer is obtained as a dispersed solid phase, i.e., pearl or bead polymerization. While the monomers may be directly dispersed in a suspension polymerization system, hydrocarbon solvents or diluents are commonly employed with the monomers, such as n-heptane, isooctane, cyclohexane, benzene, toluene, and the like, including mixtures.
In the suspension polymerization system, a monomer mixture is made up of monomer, or monomers, or, where desired, a polymer-in-monomer solution, solvent where desired, modifier, and, where employed, a free radical initiator. This mixture then is suspended in a water solution containing various suspending agents. The amount of water employed can vary widely, depending on the type of reactor employed, agitation means, and the like, though the final suspension mixture expediently will contain on the order of about 20 to 60 per cent by weight of the monomer-elastomer based on total weight of the entire mixture including water.
A variety of suspending agents can be employed in suspension polymerization systems, since the method involves a liquid-in-liquid dispersion and affords a final product in the form of discrete solid particles termed beads or pearls. The suspension stabilizers include insoluble carbonates, silicates, talc, gelatin, pectin, starch, insoluble phosphates, and the like.
The time employed for polymerization should be that sufficient for the degree or extent of conversion desired, and can vary over a wide range, depending on various reaction parameters such as the temperature employed, from a very few minutes to many hours, such as 48 hours. Temperatures employed are at least sufficient to effectuate thermal polymerization, or to cause decomposition of the free radical initiator, where used, which provides initiation of the reaction, preferably below temperatures which might cause gel formation of the polymer. Temperatures presently preferably employed are in the range of about 50°C. to 150°C.
EXAMPLES
The examples following are intended to further illustrate our invention, and not to limit the reasonable scope of invention. Particular species employed for purposes of illustration, reaction parameters, amounts or ratios employed, all are intended to assist those skilled in the art in practicing our invention, without limiting the reasonable and proper scope of our invention to which we are entitled by rights of discovery.
EXAMPLE I
A series of runs was conducted in accordance with the following recipes wherein styrene and acrylonitrile were polymerized under suspension polymerization conditions employing various modifiers.
______________________________________Monomer Solution Recipe (A) phm.sup.(a)Styrene 70Acrylonitrile 30Modifier variablet-Butyl peroctoate 0.3Suspending Agent Recipe (B) phm.sup.(a)Na.sub.3 PO.sub.4.sup.. 12 H.sub.2 O 2.45H.sub.2 O 250CaCl.sub.2.sup.. 2 H.sub.2 O 1.75H.sub.2 O 50Casein derivative.sup.(b) 0.01______________________________________ .sup.(a) Parts per hundred parts monomer .sup.(b) Cascoloid ST56 from Borden Chemical Co.
Separate solutions of sodium phosphate and calcium chloride were made in hot water and the hot solutions combined and stirred. Before cooling, supplementary case in derivative suspending agent was added.
The polymerizations were carried out by combining 50 g of monomer solution (A) and 150 g of suspending agent (B) under nitrogen in 26 oz. beverage bottles with tumbling thereof at about 80°C. for 16 hours. The polymers were recovered by acidifying the product mixtures, collecting the polymer beads on a filter, followed by washing and drying. The results are summarized in Table I.
TABLE I______________________________________Run Modifier Conversion MeltNo. Compound Amt., g. Wt. % Flow No..sup.(a)______________________________________1 iodoform 1.0 91.2 48.42 iodoform 2.0 91.0 --.sup.(c)3 chloroform 1.49 93.4 04 chloroform 2.58 94.2 05 Sulfole 120.sup.(b) 0.09 93.4 0.07______________________________________ .sup.(a) ASTM D 1238-65T, Condition G .sup.(b) A mercaptan mixture, primarily t-dodecyl mercaptan, commercially available from Phillips Petroleum Company as Sulfole* 120 .sup.(c) Immeasurably high *Trademark
As indicated by comparing the melt flow numbers of the several polymers, the organic iodide modifier iodoform clearly is superior in terms of chain transfer efficiency to the other modifiers employed.
EXAMPLE II
A series of runs was conducted in accordance with the following recipes wherein ABS polymers were prepared by suspension polymerization employing various modifiers.
Polymer Solution Recipe (A)______________________________________ Parts by Weight______________________________________Butadiene/styrene 75/25 block copolymer.sup.(a) 15Styrene/acrylonitrile 70/30 mixture 85Modifier variablet-Butyl peroctoate 0.3Dicumyl peroxide 0.1______________________________________ .sup.(a) A butadiene/styrene (75/25) block copolymer having about 18 percent block polystyrene and a Mooney viscosity ML-4 at 212° F ASTM D 1646-63 of about 47, commercially available as Solprene* 1205 from Phillips Petroleum Company.
The suspending agent recipe (B) was the same as described for Example I above.
For the polymerizations, 26 oz. beverage bottles were individually charged with 100 g. of polymer solution (A) and 300 g. of suspending agent solution (B). These were allowed to tumble at about 80°C. for 15 hours. The polymers were recovered as Runs 1-5 above. The results are shown in Table II.
TABLE II__________________________________________________________________________ Melt Izod Flexural Con- Flow Impact Modulus Ten- Elonga-Run Modifier version g/10 ft. lbs/in psi × sile tionNo. Compound Parts % min notch.sup.(a) 10-3.sup.(b) psi.sup.(c) %.sup.(c)__________________________________________________________________________6 Sulfole*120 0.4 87.8 0.08 --.sup.(d) 329 5880 237 Sulfole*120 0.5 87.5 0.57 8.58 314 5640 238 Sulfole*120 0.6 86.7 1.85 6.69 311 5340 179 Iodoform 0.4 81.5 0.45 --.sup.(d) 329 5770 910 Iodoform 0.6 82.6 3.84 0.40 336 5830 811 Iodoform 0.8 84.0 8.05 0.40 336 4670 4__________________________________________________________________________ .sup.(a) ASTM D 256-56 .sup.(b) ASTM D 790-63 .sup.(c) ASTM D 412-66 .sup.(d) Not determined?
The comparative runs illustrate by melt flow values the high effectiveness of organic iodides as modifiers. The physical properties of the iodide modified polymers were good.
EXAMPLE III
In another series of runs directed toward the synthesis of ABS polymers, the modifiers employed included elemental iodine. These runs were made in accordance with the polymerization recipes and procedures described in Example II above. The results are shown in Table III.
TABLE III__________________________________________________________________________Run Conversion Melt Flow Izod ImpactNo. Compound g. Wt. % g/10 min ft. lbs./in. notch__________________________________________________________________________12 Sulfole* 120 0.5 89.0 0.47 8.4413 Diiodomethane 0.6 89.8 0.01 1.8114 Iodine 0.6 74.3 0.44 0.76__________________________________________________________________________
In these runs, the effectiveness of another organic iodide is shown. Iodine also is seen to function as a modifier approximately as effective, on a weight basis, as a C 12 mercaptan.
Reasonable variations and modifications of our invention are possible yet still within the scope of our disclosure and without departing from the intended scope and spirit thereof. | Iodine or organic iodides are effective in suspension polymerization systems as molecular weight regulators or modifiers. These modifiers are especially suited for the suspension ABS processes. | 2 |
RELATED APPLICATIONS
This application is a Continuation-In-Part of U.S. patent application Ser. No. 13/897,430 filed 19 May 2013.
FIELD OF THE INVENTION
This invention relates to dressings and bandages for acute and chronic wounds.
BACKGROUND OF THE INVENTION
Wound management involves removal of all non-viable tissue at the wound site, preserving the remaining viable tissue, and providing a moist but not wet environment. An example of successful burn wound dressing is Biobrane, granted U.S. Pat. No. 4,725,279. In 1979 Biobrane was initially studied by American Burn Surgeons; it is still popular world-wide.
In 2007 new art was introduced by this inventor with AWBAT and then with AWBAT Plus, granted U.S. Pat. No. 7,815,931 and covered by several copending patent applications. The key to the success of these products was better porosity in the dressing.
Recently, this inventor has revisited the art of dressing design. The present invention allows passage of fluid adjacent to the wound through the primary dressing into a secondary absorbent dressing as well as improving the kinetics of uninterrupted wound healing. Technology of this dressing has evolved into a new product which possesses all the characteristics and attributes known to be important for optimal wound healing, as well as containing certain advances that result in minimization of wound desiccation and infection complication.
SUMMARY OF THE INVENTION
Wound sites have variable amounts of exudate/transudate/plasma present, from dry to weepy. The clinician must cleanly debride the wound, close it and manage wound healing in a moist but not wet environment to achieve optimal results in both acute and chronic wounds.
The present invention provides a dressing that possesses all the properties and attributes of an ideal skin substitute and, in addition, has ‘variable porosity’ controlled by the clinician from essentially zero porosity to what the wound requires. The present invention enables the clinician to move the fluid exuding from the wound through the primary dressing into an absorbent secondary dressing without disturbing the kinetics of healing or causing pain to the patient.
The present invention is cost effective at every level. Patients get their wounds managed with minimal pain and optimal healing times. The dressing is cost effective as the hospital needs to inventory only one primary dressing for acute wounds (burns) and one for chronic wounds; each has a two year shelf-life at room temperature.
The present invention is composed of one or two biological layers sprayed on in one or two separate operations. The first layer sprayed onto the nylon side of the “variable porosity” silicone membrane will be: (1) a solution of pure Aloe (Aloesin, Immuno10, Qmatrix and Loesyn—each hydrophilic and hygroscopic); (2) a solution of pure Aloe and hypoallergenic USP Pharmaceutical Grade porcine gelatin; or (3) a fine suspension of pure Aloe, gelatin and ECM (as fine insoluble particles or hollow spheres in water—the latter possesses improved healing properties). In vitro, the Aloe component has been demonstrated to cause a variety of cells to attach and proliferate; as well as increase synthesis of collagen and alpha smooth muscle actin. ECM may be added to the biologicals described above and is a mixture from human fibroblasts that is known to cause rapid cell proliferation and tissue growth. Previous wound dressings and skin substitutes, as taught in U.S. Pat. No. 7,815,931 contain gelatin, a pure Aloe component, chondroitin 4 & 6 sulfate, and vitamin C & E. In contrast the current dressing will have two layers of biologicals applied in separate spraying operations as described above.
The first coat will contact the wound after the second coat of hypoallergenic bovine spongiform encephalopathy (BSE)-free United States Pharmaceutical (USP)-grade gelatin interacts with fibrin in the wound to achieve early adherence. The second coat of biologicals stimulates the healing process during the interval where the dressing invention is in contact with the wound and is stable requiring 100 degree water for 30 minutes to remove from the “variable porosity” silicone/nylon surface.
Water soluble or water insoluble anti-scar compound(s) can be incorporated into the 3D matrix of this variable porosity skin substitute. The preferred embodiment of the anti-scar compound is salinomycin, which can be incorporated in two ways—into the hydrophobic solid silicone component of the skin substitute or into the water soluble biological coating used to coat the 3D surface.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 . The embodiments of the invention, showing the slit openings
FIG. 2 . The wale and course nature of the woven fabric
FIG. 3 . An example of punctuate scarring
DETAILED DESCRIPTION
The present invention is similar in composition to earlier skin substitutes in that they each have a thin silicone component, the silicone membrane selected in a thickness from 0.001″ to 0.005″, and an underlying thin knitted nylon component. The present invention differs from its ancestors in that it has “variable porosity” controlled by the clinician; the pore size in the thin silicone will be essentially zero (with no stretch, in relaxed mode) to a higher porosity (proportional to the stretch applied). See FIG. 1 for the optional stretch modes. In addition, the present invention differs in the composition of biological coatings applied to both components and how these coatings interact with the wound over time.
The pores of prior art skin substitutes/dressings are of a fixed size (Biobrane 1.2%; AWBAT and AWBAT Plus 5.5% and 7.5%) in the unstretched open position; the silicone is cured while the skin substitute pores are open. Once cured the pores cannot close or be reduced in size; this causes wound desiccation and punctate scarring. As in FIG. 1 , in contrast, the openings are made after the silicone component has been cured, and are in the shape of slits, not holes. The figure shows the skin substitute silicone layer up with the slits exposed.
The “wale” and “course” orientations of stitching of the knitted nylon component of the invention are shown in FIG. 2 . The preferred embodiment of the invention is shown in FIG. 1 . In this embodiment, designed for burns, the slits 103 made in the silicone are approximately 0.250″ long 101 with a space of 0.250″ between slits 102 ; parallel rows of slits are 0.250″ apart. The parallel rows of slits are oriented such that the slits are parallel to the “wale” orientation of the Jersey stitch pattern of the knitted nylon component. The “wale” orientation has measurably less elongation than the “course” orientation.
Because of the orientation of the slits, stretch along the axis of the slits is minimal and stretch perpendicular to the slit axes is maximized. With no stretch of the silicone/nylon membrane the slits cannot be seen without magnification while observing from above and provide essentially zero porosity.
The preferred embodiment is effective, particularly on partial thickness burns where punctate scarring has been observed. In the preferred embodiment, with no stretch, the wound is protected by an essentially continuous thin silicone membrane which minimizes wound desiccation and punctate scarring. This enables the clinician to stretch the dressing parallel to the direction of the slits with minimal opening of the slits. This is parallel to the “wale” direction of the underlying fabric. Fluids from the wound can still escape through the closed slits and be absorbed into a secondary dressing, which can be removed and replaced without interfering with the healing process or causing pain to the patient.
The combination of a primary dressing that requires minimal changes and a secondary dressing that is easy to change and replace reduces wound maintenance costs which benefits patient, staff and hospital. An example of punctate scarring is illustrated in FIG. 3 ; the figure shows the skin of a patient whose burn was covered with the ancestor AWBAT dressing with a fixed porosity of at least 5.5%.
Chronic, slow healing wounds require similar treatment as burns in that all necrotic tissue must be removed before closing the wound with a primary dressing. In the chronic wound, exudate and other fluids are often removed with negative pressure wound therapy (NPWT). A negative pressure above the wound or a positive pressure from the wound causes exudate and other wound fluids to pass through the primary dressing into a secondary dressing. The primary dressings currently used during NPWT are: urethane foam, polyvinyl alcohol foam or cotton gauze; all require frequent dressing changes and infection complications have been reported when these dressings are not changed frequently.
The present invention will have two layers of water-soluble biologicals; first a clotting outer layer containing hypoallergenic BSE free USP Pharmaceutical grade gelatin. This layer contacts the wound first and stimulates initial adherence of the dressing to the cleanly debrided wound. The second layer of pure Aloe or Aloesin, pure Aloe and BSE free gelatin, or a mixture of pure Aloe, BSE free gelatin and ECM interact with the wound to stimulate the rate of healing while adherent to the wound. The first layer is deposited directly on the nylon side of the “variable porosity” silicone/nylon surface and is stable, i.e. requires 100 degree water for 30 minutes to remove from the “variable porosity” silicone/nylon surface.
Water soluble or water insoluble anti-scar compound(s) can be incorporated into the 3D matrix of this variable porosity skin substitute. The preferred embodiment of the anti-scar compound is salinomycin, which can be incorporated in two ways—into the hydrophobic solid silicone component of the skin substitute or into the water soluble biological coating used to coat the 3D surface. The structure of salinomycin is shown below.
In one embodiment, salinomycin is formulated in a topical composition comprising salinomycin and a carrier or excipient suitable for dermal application. The term “carrier or excipient” as used herein, refers to a carrier or excipient that is conventionally used in the art to facilitate the storage, administration, and/or the biological activity of an active compound. A carrier may also reduce any undesirable side effects of the active compound. A suitable carrier is, for example, stable, e.g., incapable of reacting with other ingredients in the formulation. In one example, the carrier does not produce significant local or systemic adverse effect in recipients at the dosages and concentrations employed for treatment. Such carriers and excipients are generally known in the art. Suitable carriers for this invention include those conventionally used, e.g., water, saline, aqueous dextrose, and glycols are preferred liquid carriers, particularly (when isotonic) for solutions. Suitable pharmaceutical carriers and excipients include starch, cellulose, glucose, lactose, sucrose, gelatin, malt, rice, flour, chalk, silica gel, magnesium stearate, sodium stearate, glycerol monostearate, sodium chloride, glycerol, propylene glycol, water, ethanol, and the like. Suitable carriers for topical application of a compound are known in the art and include, for example, methyl cellulose (e.g., 3% methylcellulose; Beck et al., Growth Factors, 3: 267, 1990), silver sulfadiazene cream (Schultz et al., Science, 235: 350, 1985), multilamellar lecithin liposomes (Brown et al., Ann Surg., 208: 788, 1988) or hyaluronic acid (Curtsinger et al., Surg. Gynecol. Obstet., 168: 517, 1989). In some examples, the carrier can be a co-polymer, a paste or a hydrogel.
In some embodiments, the topical composition as described herein according to any embodiment additionally comprises a compound that enhances or facilitates uptake of salinomycin into and/or through skin of a subject. Suitable dermal permeation enhancers are, for example, a lipid disrupting agent (LDA), a solubility enhancer, or a surfactant.
This is the preferred embodiment of the invention. The technology to create this invention is listed as the preferred embodiment of this invention, but other methods are possible and are within the contemplation of this patent. | An improved skin substitute is presented comprised of a silicone layer backed up with a woven nylon fabric layer, the silicone layer possessing a regular pattern of slits that permit the porosity of the skin substitute to be adjusted by clinicians by means of applying tension to the skin substitute that differentially opens the slits. A variety of therapeutic substances can be applied to the skin substitute to promote healing, including aloe and other medicinal preparations. A layer of water soluble or water insoluble anti-scar compound is also present, the preferred compound being salinomycin. | 3 |
This in a continuation of application Ser. No. 08/745,599, filed Nov. 8, 1996, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a drawer system for storing and transporting tools, machinery parts, building materials and the like on vehicular load-carrying surfaces, such as the beds of pickup trucks or the cargo-carrying floors of utility vehicles. More particularly, the invention relates to an easily-installable accessory-type drawer system of modular, stackable construction adaptable to a wide variety of configurations and volumetric space requirements depending upon the particular vehicle in which the system is to be installed.
Modular stackable drawer systems for various applications are well known, such as those shown in Smith U.S. Pat. No. 129,688 and Belgian published patent application No. 547,130. However drawer systems suitable for use in vehicles must normally be custom built to fit each particular vehicle's configuration and space requirements in order to secure the drawer system against the dynamic forces of braking, acceleration, turning and vertical oscillation commonly encountered in vehicles. Existing modular stackable drawer systems are not well adapted to maintain stable positions and resist movement under such dynamic conditions.
Existing modular drawer systems are also not well adapted to provide stable, yet lightweight, resistance to vertical loading in vehicles. This is likewise due to the lack of resistance of existing drawer systems to dynamic conditions, as well as deformation of the walls of such systems when subjected to vertical loads, which impedes the slidability of the drawers.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the foregoing deficiencies of present drawer systems with respect to dynamic vehicular conditions.
According to one aspect of the invention, a modular, stackable drawer system particularly adapted for installation on vehicular load-carrying surfaces has a plurality of elongate rectilinear housings and a plurality of elongate drawers each matingly slidable longitudinally within a respective one of the elongate housings. At least the top of a first housing and the bottom of a second housing have mutually-mating respective exterior surfaces enabling longitudinally-aligned detachable engagement therebetween in a manner resistive to sliding movement between the first and second housings both longitudinally and transversely when the second housing is stacked atop the first housing. The bottom of at least the first housing has at least one vehicle-engaging fastener enabling detachable fastening of the housing to a load-carrying surface of a vehicle so as to prevent sliding movement between the first housing and the load-carrying surface, likewise both longitudinally and transversely.
Preferably the vehicle-engaging fastener is attachable to the load-carrying surface of the vehicle in a manner preventing vertical oscillation between the first housing and the load-carrying surface as well.
The foregoing features of the present invention provide an accessory-type, dynamically stable vehicular modular drawer system which is highly variable in configuration and volumetric space requirements so as to adapt to almost all vehicle configurations by arranging the drawer module assemblies in any side-by-side and/or stacked configuration.
Moreover, in accordance with another aspect of the invention, the modular drawer assemblies are designed to provide significant vertical resistance to overhead loading from other like drawer assemblies, or from other loads, without deforming sufficiently to interfere with the slidability of the drawers located beneath the loads.
In accordance with another aspect of the invention, the mating respective slide surfaces of each drawer and its housing form respective single homogeneous pieces with the drawer and housing.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective exploded view of an exemplary embodiment of the drawer component of a modular drawer assembly in accordance with the present invention.
FIG. 2 is a perspective view of a housing into which the drawer of FIG. 1 is insertable.
FIG. 3 is a sectional view of a pair of housings of the type shown in FIG. 2, one atop the other, the section being taken along line 3--3 of FIG. 2 and the bottom housing having the drawer of FIG. 1 inserted therein.
FIG. 4 is a sectional view similar to that of FIG. 3, except that the section is taken along line 4--4 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
An exemplary modular drawer assembly includes an elongate housing 12 and an elongate drawer 14 matingly insertable longitudinally into the housing 12 through its open end 13. The housing 12 has a generally rectilinear tubular cross section having a top wall 16, bottom wall 18 and sidewalls 20, 22 all extending longitudinally between the opposite ends of the housing 12. The end 15a of the housing is closed by an end panel (not shown). The top and bottom walls 16 and 18 are preferably wider than the height of the sidewalls 20 and 22 so that the drawer assembly has a low center of gravity relative to its width for high resistance to side tipping. The significantly elongated form of the drawer assembly shown in FIGS. 1 and 2 is especially suitable for side-by-side and stacked placement upon the bed of a pickup truck or van. A shorter form of the drawer assembly (not shown) is suitable for sports/utility vehicles having shorter beds.
The housing 12 and drawer 14 are preferably constructed of high-density polyethylene having thicknesses of approximately 3/16 inch for the housing and 1/8 inch for the drawer, respectively. Preferably, a conventional rotational molding process is used to form the housing, and a conventional vacuum molding process is used to form the drawer. The housing and drawer could alternatively be constructed from other suitable waterproof and rust-resistant materials, such as ABS, PVC, or aluminum.
Located proximate to each respective sidewall 20, 22 of the housing 12 are respective upwardly-facing, transversely-spaced interior slide surfaces 24 and 26, each forming a single homogeneous piece with the housing 12 as shown in FIGS. 3 and 4. Such slide surfaces need not contact the sidewalls directly, as shown, but could alternatively be spaced inward from the sidewalls supported entirely by the bottom wall 18 of the housing, in the same manner as the optional central slide surface 25. These slide surfaces 24, 25 and 26 slidably engage downwardly-facing, transversely-spaced exterior slide surfaces 28, 29 and 30 on the bottom of the drawer 14, each likewise forming a single homogeneous piece with the drawer. Spaces such as 27 are preferably provided between nonslide surfaces on the bottoms of the drawer and housing, to facilitate slidability of the drawer.
As shown in FIGS. 3 and 4, the sliding engagement of the slide surfaces supports the drawer 14 in vertically-spaced relation to the top wall 16 of the housing to resist the application of force by the top wall against the drawer under loading applied perpendicular to the top wall by like drawer assemblies or other overhead loads. Resistance to such force is also provided by exterior elongate protruding ribs 23 on the sidewalls 20, 22 extending perpendicular to the top wall 16, which resist bending of the sidewalls under such loading. Both of these features cooperate to maintain slidability of the drawer by minimizing frictional resistance to sliding despite overhead loading of the drawer assembly.
The drawer 14 has a face panel 40, with a handle 41, and an end panel 42, likewise spaced from the housing top wall 16. The entire drawer fits slidably within the confines of the housing 12 so that the housing forms a rain-proof enclosure around the drawer.
One or more detachable transverse partition panels 44 or 44a are optionally provided for sliding insertion into selected ones of grooves 45 formed on the interior surface of the drawer sidewalls 32 and 34. Partition panel 44a has an aperture 44b extending therethrough for accommodating particularly long items to be placed in the drawer. Longitudinal rectangular partition panels (not shown) may also be provided for alternative insertion between end grooves 47, or diagonally between two opposite corners such as 40a and 42a. Shallow grooves (not shown) in the bottom of the drawer can also be provided if desired to capture the bottoms of the various partition panels. The top of each partition panel is likewise spaced from the top wall 16 of the housing when fully inserted.
The spaces 35 between all of the foregoing components of each drawer 14 and the top wall 16 of each housing 12 are small enough that such spaces will close before any nonelastic deformation of the housing 12 due to overhead loads can occur, thereby resisting such excessive deformations. Such excessive deformations might otherwise occur, for example, as a result of dynamic vertical oscillations from uneven road surfaces which change the static overhead loads temporarily into dynamic loads which might permanently deform or rupture a housing 12.
The top and bottom of each housing 12 have mutually-mating respective exterior surfaces enabling longitudinally-aligned detachable stacking engagement therebetween so as to prevent sliding movement between the housings both longitudinally and transversely when dynamic forces from braking, acceleration and turning are experienced. Although such mutually-mating exterior surfaces may, within the scope of the present invention, be provided by such means as tape having double-sided adhesive, or mating hook and loop material, such surfaces are preferably composed of mating interlocking contours on the top and bottom surfaces of each housing 12. For example, depressions 16a and protrusions 16b on the top 16 of each housing interlock receptively with mating protrusions 18b and depressions 18a, respectively, on the bottom 18 of each housing to prevent both longitudinal and transverse sliding movement between the housings when they are stacked one atop the other as in FIGS. 3 and 4.
The bottom 18 of each housing 12 in contact with a vehicular load-carrying surface 46, such as a pickup truck bed or utility vehicle cargo floor, has vehicle-engaging fasteners 48 enabling detachable fastening of the housing to the vehicle load-carrying surface to likewise prevent such longitudinal and transverse sliding movement. Preferably, the fasteners comprise tape having double-sided adhesive, or mating hook and loop material. Such fasteners resist not only longitudinal and transverse dynamic forces, but also oscillatory vertical dynamic forces typical of vehicles which might tend to bounce the drawer assemblies upward from the load-carrying surface.
If desired, such fasteners can also be inserted between stacked housings to resist oscillatory vertical dynamic forces. Alternatively, straps can be wrapped around a group of stacked housings to resist such forces.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | A modular drawer system is particularly adapted for installation on vehicular load-carrying surfaces such as the beds of pickup trucks and the cargo-supporting floors of utility vehicles to transport and store tools, machinery parts, building materials and the like in an orderly, easily-accessible manner. The system's modularity provides highly variable alternative stacked configurations and volumes to accommodate different vehicles. Although lightweight and easily installable, the system nevertheless is highly resistant to displacement under the dynamic forces typically experienced in vehicular applications, and is also highly resistant to vertical loading. | 1 |
TECHNICAL FIELD
The present application relates to a method for controlling a pressure fluid flow in a pressure pulse generator.
The invention also relates to a device for generating pressure pulses.
The invention is applicable to all types of technical areas were pressure pulses are to be generated. In particular it is applicable to applications on which there are high requirements on the speed with which pulses can be generated and on the time period of the individual pulses.
Internal combustion engines define a field in which pressure pulses can be used for controlling and effecting the movements of the valves of the combustion engine instead of operating and controlling the movements of the inlet, outlet or fuel injection valves by means of a conventional transmission of the motion of the piston of the engine to the valves by means of a camshaft. The invention can also by used for controlling and operating a piston arranged for the purpose of achieving a variable compression in a combustion engine cylinder.
Accordingly, the invention will, by way of example, and not in a delimiting purpose, be described with reference to the application in which it is used for the control of and operation of the inlet or outlet valves of the combustion chamber of a combustion engine.
THE BACKGROUND OF THE INVENTION
Since a number of years designers of piston combustion engines have seen a need of being able to vary the valve times during engine operation, since this would result in great advantages with regard to, for example, fuel economy and emissions.
Therefore, extensive efforts have been made in order to replace conventional camshaft systems for the opening and closure of engine valves by systems that are based on the use of electromagnetism for controlling and operating the valves of the engine. The disadvantage of such solutions is that the high requirements on the speed by which the valves can be operated will result in high requirements on the electromagnets that are used. The mass that each electromagnet has to bring into motion corresponds to the mass of the valve. The valve must comprise a suitable magnetic material in order to be displaced by the action of one or more electromagnets, and such materials contribute to an increase of the mass of conventional valves. This often results in an evil circle in which an improvement of a valve from a magnetic point of view will result in a weight increase that, in its turn, results in a need of larger and more powerful electromagnets. Accordingly, in this way, it will be difficult to achieve an economically and practically good solution to obtaining a sufficiently fast control and operation of the valves of the engine. Moreover, it is well known that electromagnets will require a certain time for magnetising and demagnetising.
There are also efforts being made to obtain the requested movements of the engine valves by means of hydraulics. Today, such systems are tested by, amongst others, vehicle manufactures. The pressure fluid, here the hydraulic liquid, is in this case used in order to effect the engine valve movement. Thereby, it is required that the pressure pulse generator that is used has an ability to deliver the pressure pulses that cause the valve movements rapidly and with high precision. The present inventor does not know any pressure pulse generator according to prior art that has the performance required to satisfyingly cope with the valve control at the rotations per minute of the engine that are used today in two-stroke, and, in particular, four-stroke combustion engines. An obstacle to the accomplishing of such a pressure pulse generator may be the difficulty to achieve sufficiently rapid opening/closure movement of the valve or valves that is/are required in such a pressure pulse generator. Here, it should be mentioned that valves are often replaced by ports in modern two-stroke engine constructions, but that the present invention results in the possibility of using valve technology in two-stroke engines in a way corresponding to that of four-stroke engines.
In this context, it should also be mentioned that the pressure pulse generators that may come in question should be compact and occupy only a small space in combustion engine applications.
THE OBJECT OF THE INVENTION
One object of the present invention is to provide a method and a device that enable generation of pressure fluid pulses with very high frequency and precision.
A further object is to provide a method and a device that make it possible to deliver pressure pulses with high frequency and precision with maximum use of the pressure fluid, i.e. without any pressure fluid loses in the pressure fluid circuit or circuits.
A further object is to provide a method and a device that make it possible to, with so few and uncomplicated components as possible, in particular with as few electro magnets as possible, generate pressure pulses with high frequency and precision.
A further object of the invention is to provide a method and a device for pressure pulse generation that are applicable to combustion engines for controlling and operating individual inlet, outlet and injection valves (for fuel or water). The invention shall also be able to act as a driving apparatus for a piston for accomplishing a variable compression ratio in a combustion engine.
Another object is to provide a method and a device for pressure pulse generation, that create the conditions for or, in practice, permits a transition from two-stroke operation to four-stroke operation and vice versa in a combustion engine the valves of which are controlled by a device according to the invention that operates in accordance with the method according to the invention.
SUMMARY OF THE INVENTION
The main object of the invention is achieved by means of the initially defined method, having the features that are defined in the characterising portion of patent claim 1 , and by means of a device as initially defined, having the features that are defined in the characterising portion of patent claim 12 .
Preferred embodiments of the method that contributes to the achievement of the objects of the invention are defined in the dependent patent claims 2 – 11 .
Preferred embodiments of the device that contribute to the achievement of the object of the invention are defined in the dependent claims 13 – 25 .
Further features and advantages of the method and the device according to the invention will be seen from the following, detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall now be described by way of example with reference to the annexed drawings on which:
FIG. 1 is a diagram that shows a first embodiment of a device according to the invention, schematically and in cross section, in a start position,
FIG. 2 is a diagram corresponding to the one of FIG. 1 , but with the device shown during a first stage,
FIG. 3 shows the device according to FIGS. 1 and 2 during the end of the first step,
FIG. 4 shows the device according to FIGS. 1–3 during a continued motion,
FIG. 5 shows the device according to FIGS. 1–4 during a second stage,
FIG. 6 shows an alternative embodiment of a part of a circuit of the inventive device,
FIG. 7 shows a second embodiment of the device according to the invention, in a first stage, with the circuit shown in FIG. 6 included,
FIG. 8 shows the device according to FIG. 7 , in a second stage,
FIG. 9 shows a third embodiment of the device according to the invention, in a first stage, and
FIG. 10 shows the device according to FIG. 9 in a second stage.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a first embodiment of a device according to the invention, the device being generally designated with 1 and comprising a pressure fluid circuit 2 , a first valve body 3 , which is positioned in a first chamber 4 , a second valve body 5 , which is positioned in a second chamber 6 , a pressure fluid source 7 , a pressure fluid depression 8 , a first valve that comprises an electro magnet 9 and a third valve body 10 driven by said electro magnet, a second valve that comprises a second electro magnet 11 and a fourth valve body 12 driven by the latter.
Further, the device comprises a cylinder 13 and an actuator piston 14 which is displacebly arranged in the latter. The pressure fluid circuit 2 communicates with and is arranged to deliver pressure fluid pulses on one side of the piston 14 , for the displacement of the latter. The piston 14 is, via a valve shaft 16 , connected with a valve 17 , to a combustion chamber of a combustion engine. The valve 17 could, however, as well be a valve for injection of fuel to the combustion chamber of a combustion engine or could be connected with or form a piston in a cylinder connected with the combustion chamber for the purposes of accomplishing a variable compression ratio, the position of the valve and variable compression piston respectively in relation to a cylinder of the combustion engine being controlled by the pressure fluid pulses.
Preferably, the pressure fluid is gaseous and, most preferably, it is constituted by air or carbon dioxide. In the applications referred to above, the pressure fluid source 7 is, preferably, a compressor with a tank associated thereto, or a pressure tank exclusively, associated to the combustion engine, and the pressure fluid depression is any site that has a lower pressure than the air pressure generated by the compressor or the pressure existing in the pressure tank.
The pressure fluid circuit 2 comprises a first branch 18 and a second branch 19 , which branch off from the pressure fluid source 7 and extend to opposite sides of the first valve body 3 in the first chamber 4 . From one of the sides of the first valve body 3 in the first chamber 4 a conduit 20 leads to the pressure fluid depression, and on the other side of the first valve body 3 there is an opening 21 , the periphery of which forms a seat for the valve body 3 , the first chamber, or the high pressure side of the pressure fluid circuit 2 , being able to communicate with the cylinder chamber 15 through opening 21 . The first branch communicates with a first chamber 4 on the side of the first valve body 3 where the opening 21 is located.
In the shown embodiment, a first chamber 4 is in constant communication with the pressure fluid source 7 branch 18 via the first branch.
The device 1 also comprises a third branch 22 and a fourth branch 23 , which branch off from the pressure fluid depression 8 and pressure fluid source 7 respectively and extend to opposite sides of the second valve body 5 in the second chamber 6 . A fifth branch 24 extends from the pressure fluid depression 8 to one side of the second valve body 5 in the second chamber 6 , and on the other side of the second valve body 5 there is an opening the periphery of which forms a seat for the valve body 5 , the second chamber, or the low pressure side of the pressure fluid circuit, being able to communicate with the cylinder chamber 15 through the opening 25 .
The third branch communicates with the second chamber 6 on the side of the second valve body 5 where the opening 25 is located. That of the areas of the valve bodies 3 and 5 onto which the pressure fluid of the pressure fluid circuit acts in one direction, here the closure direction, is larger than the opposite area in chambers 4 and 6 on which the pressure fluid acts in the opposite direction, when valve bodies 3 and 5 rest against the periphery of the openings, i.e. a region or an edge around the openings 21 , 25 , and close the latter. Moreover, the surface that covers the opening 21 , 25 is smaller than the first-mentioned area of each individual valve body. The valve bodies 3 , 5 are designed as disk valves.
In the embodiment shown, the second chamber 6 is in constant communication with the pressure fluid depression 8 via the third branch 22 .
The device comprises a first electrically activateable valve member for opening/interrupting of the communication between the first chamber 4 and the pressure fluid source 7 , and a second electrically activateable valve member for the opening/interruption of the communication between the first chamber 4 and the pressure fluid depression via said conduit. The first and the second valve members are formed by the first electro magnet 9 and the valve body 10 driven by the latter, said valve body defining a decompressed slide valve. The first valve member is arranged to open when the second valve member closes and vice versa. This is achieved as the valve body 10 is a equipped with at least one channel or passage (not shown) that, upon activation of the electro magnet, is displaced in front of (an exact centring is not required but is preferred) of one of the conduit 20 or the second branch 19 , and is displaced to a position in front of the other one of the conduit 20 and the branch 19 deactivation of the electro magnet 9 .
The device comprises a spring element 26 for displacing the first valve body 10 when the electro magnet 9 is deactivated. This will be explained more in detail later.
According to the alternative embodiment shown in FIGS. 6–10 , the device comprises a third valve member formed by the second electro magnet 11 and the valve body 12 associated thereto, said third valve member being provided for opening/interruption of the communication between the first chamber 4 and the pressure fluid depression 8 through the conduit 20 . In this case, the third member is located upstream the second valve member. Upon activation of the second electro magnet 11 , the third valve member opens for communication in the conduit 20 , and upon deactivation of the electromagnet said valve member interrupts the communications.
The device, according to all the embodiments shown, further comprises a fourth valve member formed by the second electro magnet 11 and the valve body 12 associated thereto, the fourth valve member being arranged for opening/interruption of the communication between the pressure fluid source 7 and the second chamber 6 through the fourth branch 23 . Furthermore, the device comprises a fifth valve member formed by the second electro magnet 11 and the valve body 12 associated thereto, said fifth valve member being arranged for opening/interrupting the communication between the second chamber 6 and the pressure fluid depression 8 . The fourth valve member is arranged to open when the fifth valve member interrupts and vice versa. This can be achieved by letting the valve body 12 comprise at least one channel or opening that, upon activation of the second electro magnet 11 , is displaced to a position opposite to one of the fourth branch 23 and the fifth branch 24 , and, upon deactivation of the same is displaced to a position in which it is located opposite to the second one of the fourth and fifth branch 23 , 24 .
In the embodiments according to FIGS. 7–10 , the third valve member is arranged to open in the conduit 20 when the fourth valve member opens for communication between the pressure fluid source 7 and the second chamber 6 through the fourth branch 23 , that is when the fourth member closes for communication between the pressure fluid depression 8 and the second chamber through the fifth branch 24 .
The device comprises a spring element 27 for displacing the second valve body 12 when the second electro magnet 11 is deactivated. This will be explained more in detail later.
In the third embodiment that is shown in FIGS. 9 and 10 , the device comprises a sixth branch 28 , through which the first chamber 4 communicates with the pressure fluid source 7 , and a sixth valve member, formed by the second electro magnet 11 and the valve body 12 associated thereto, for the purpose of enabling and interrupting the communication between the first chamber 4 and the pressure fluid source 7 through the sixth branch 28 . The sixth valve member is arranged to open when the fifth valve member opens, i.e. when the fourth valve member closes.
Further, the device comprises a sensor 29 , for example an optical or inductive sensor, which registers the position of the actuator piston 16 or any part connected thereto. The sensor 29 is operatively connected with a control unit (not shown) that, based on the signal from the sensor, activates or deactivates the first and the second electro magnet 9 , 11 . Furthermore, the device comprises a sensor (not shown) for sensing the position of that cylinder of a combustion engine to which the valve actuator is associated. The control unit, which is also operatively connected with this sensor, may then be arranged to control the electro magnets 9 , 11 based on the information from this sensor.
As has been mentioned earlier, the device comprises spring elements 26 , 27 that act for a redisplacement of the valve bodies 10 , 12 that have been displaced when the electro magnets 9 , 11 have been deactivated, that is when the latter let the valve bodies 10 , 12 loose. In this case, the spring elements 26 , 27 are pressure fluid regulated as one surface of the valve bodies 10 , 12 associated thereto can communicate through a branch or a conduit, in this case constantly, with pressure fluid source 7 , and a second, opposite surface can communicate through a further branch or conduit, in this case constantly, with the pressure fluid depression 8 . The high pressure side is, in this case, arranged to counteract the electro magnet and redisplace the valve body 10 , 12 upon said deactivation. It is also conceivable that one of the surfaces communicates with the atmosphere and that the other surface communicates with the pressure fluid depression, given that the latter has a higher pressure than the atmosphere pressure (we assume that the surfaces are equally large).
Apart from the components already mentioned, the device preferably comprises at least one hydraulic brake and locking arrangement, that comprises a hydraulic circuit that consists of a conduit 30 that runs from a pressure source (not shown), which for example may comprise the oil pump of a combustion engine, to a chamber 31 , in which a piston shaft 32 connected with actuator piston 16 penetrate at least some time during the displacement of the actuator piston, preferably when the inlet valve 17 associated to the latter reaches a home position in which it is positioned in its seat in the cylinder top. The device has a valve, preferably a non return valve 41 , that opens for communication between the liquid source and the chamber 31 through the hydraulic liquid conduit 30 and closes in the opposite direction. Furthermore, there is a down stream conduit 33 through which the chamber 31 can communicate with a low pressure side 34 in the hydraulic circuit, for example the oil pan of a combustion engine.
The chamber 31 comprises a constriction 37 , through which the piston shaft 32 will move, the constriction 37 or the piston shaft being arranged in such a way that a slot is generated between them, said slot being reduced during said motion. For example, this is achieved by, as here, the end of the piston shaft 32 being conical. In that way, an increasing braking effect is achieved in said direction as the liquid that is forced away by the piston shaft 32 in the chamber 31 get an increasingly small slot for its removal as the piston motion continues. The hydraulic liquid that is heated during the braking is thereby transported away through the downstream conduit 33 .
The device comprises an activatable valve 35 for opening/interruption of the communication through the downstream hydraulic liquid conduit 33 . The valve 35 forms a decompressed slave valve and is, through a seventh branch 36 , connected with the second chamber 6 , or with the fourth branch and fifth branch that for the moment opens for pressure fluid communication between the second chamber and pressure fluid source or pressure fluid depression respectively. The pressure fluid in the seventh branch 36 acts against the surface of the valve 35 for the purpose of displacing the latter in a direction towards a position in which it closes. On an opposite surface there is a counter force, in this case constituted by the hydraulic liquid in the downstream hydraulic liquid conduit 33 , for the purpose of displacing the valve to a position in which it closes, i.e. interrupts, the communication with the downstream conduit 33 . The pressures and areas of the surfaces that are effected by pressure fluid and the pressure liquid respectively are adapted in such a way the slave valve 35 opens for communication through the conduit 33 when the seventh branch 36 communicates with the pressure fluid depression 8 , and closes said conduit 33 when the seventh branch 36 communicates with the pressure fluid source 7 .
A cycle of the device according to the invention according to a first embodiment will now be explained with reference to, primarily, FIGS. 1–5 .
In FIG. 1 , the device is shown in a starting position in which the two electro magnets 9 , 11 and the valve bodies 10 , 12 associated thereto are deactivated, whereby the engine valve 17 is in its home position, in which it rests against its seat. The pressure fluid source 7 communicates with the first chamber 4 on both sides of the first valve body 3 , and since the side of the body 3 that is directed away from the opening 21 is larger than the area of the opposite side the valve is closed. In a corresponding way, the pressure fluid depression communicates with the second chamber 6 on both sides of the second body 5 , which, accordingly, closes the opening 25 associated thereto.
In FIG. 2 , the device is shown in a position just after that the first electro magnet 9 has been activated following an order from a control unit based on a sensor measurement of the position of the piston in the combustion engine cylinder in question. As a result of the activation of the first electro magnet 9 , the first valve body 10 , interrupts the communication between the first chamber 4 and the pressure fluid source 7 through the second branch. The pressure by which the pressure fluid acts on the first valve body 3 through the first branch makes the valve body move away from the opening 21 and, thereby, permits pressure fluid to flow into the chamber 15 and, thereby, displace the actuator piston 14 and the valve 17 from the home position. The displacement of the valve from the home position takes places, in a conventional way, against the action of a valve spring 40 .
Also the second electro magnet 11 has been activated and, thereby, permits a communication between the pressure fluid source 7 and the second chamber 6 through the fourth branch 23 . Thereby, the second valve body 5 is prevented from being displaced from the opening 25 associated thereto, which would result in the fluid being able to flow from the chamber 15 through said opening 25 .
In FIG. 3 there is shown a subsequent stage, during which the first electro magnet 9 has been deactivated and the valve body 10 associated thereto has been redisplaced to its starting position through the action of the spring element 26 . The first valve member is once again open for communication between the first chamber 4 and the pressure fluid source 7 through the second branch 19 , resulting in the first valve body 3 , which is located in the first chamber, having been redisplaced to a position in which it closes the first opening 21 . Due to the continued expansion of the pressure fluid in the chamber 15 , and to the kinetic energy of the displaced mass, the motion of the actuator piston 14 and the valve 17 continues a bit further.
It should be noted that the slave valve 35 , through the seventh branch 36 and through the fourth branch 23 , communicates with the pressure fluid source 7 , thereby interrupting any evacuation of hydraulic liquid through the downstream conduit 33 , but that an inflow through the upstream conduit 30 is permitted. This results in the hydraulic circuit being able to act as a lock when the valve 17 reaches its remote position or lower dead, up to the point when the slave valve 35 is once again brought to its opening position.
In FIG. 4 , only the continued motion of the actuator piston 14 and the valve 17 associated thereto towards the remote position is shown, the valve possibly being temporarily locked before the deactivation of the second electro magnet.
In FIG. 5 the device is shown in a subsequence stage, after the deactivation of the second electro magnet 11 and the displacement of the valve body 12 associated thereto through the action of the associated spring element 27 to a position in which the second chamber 6 once again communicates with the pressure fluid depression 8 through the fifth branch 24 . The valve body 5 located in the second chamber 6 has, by the pressure from the fluid in the chamber 15 , been displaced away from the opening 25 , and pressure fluid is permitted to flow out from the chamber 15 through the third branch 22 to the pressure fluid depression 8 while the actuator piston 14 and the valve 17 connected thereto are displaced towards the home position.
It should be noted that the slave valve 35 has been displaced to its opening position and, thus, does not any longer lock the valve 17 in its remote position, since the seventh branch 36 is now communicating with the pressure fluid depression 8 through the fifth branch 24 .
When the pressure in the chamber 15 has been reduced to such a degree that the valve has reached its home position, the second valve body is closed due to the effect of the gravitational force and/or its upper side once again being brought into communication with the pressure fluid source before the next cycle. Thereby, a return to the starting position of FIG. 1 is achieved.
It should be realized, as also has been shown in the drawings, that each of the valve bodies 10 , 12 may comprise a plurality of openings or passages for the accomplishment of a communication in the conduits and branches in question in accordance with the teaching of the application in general.
It should be realized that the electro magnets used may be a pushing type or pulling type of magnets.
In the case in which the device is used for accomplishing a variable compression ratio, the valve 17 should be replaced by a corresponding piston in such a device. The piston is then arranged in a cylinder that directly communicates with the combustion chamber. Also in the case when the device forms an injection valve, the valve 17 should be replaced by a piston.
The device may also be used for the expansion of gases, whereby the gas/air pulses that are created can be used in air motors, and in general for the transmission of gas pulses into mechanical movement.
A particular advantage of the invention is that it uses a minimum number of electro magnets and valve bodies associated thereto for the opening/interruption of the described conduits and branches in the pressure fluid circuit 2 . Accordingly, one electro magnet 9 is used for the opening/closure of the second branch 19 and the conduit 20 through a displacement of the valve body 10 associated thereto. A further electro magnet 11 is used for the opening/closure of the forth and fifth branch 23 , 24 and of the conduit 20 and the sixth branch 28 through the displacement of the valve body 12 associated thereto. | A device for generating pressure pulses, includes a pressure fluid source and a pressure fluid depression, a pressure fluid circuit, a valve body displaceably located in a chamber, a first branch and a second branch the branches leaving to opposite sides of the valve body, the chamber having an opening on one side of the valve body, the opening communicating with the first branch and permitting pressure fluid to flow out of the chamber. The valve body, under the action of the pressure fluid in the branches, is displaceable to a first position in which it closes the opening and to a second position in which it leaves the opening open for out-flow of the pressure fluid. The device includes a first valve member arranged to permit or interrupt communication between the chamber and the pressure fluid source through the second branch upstream of the chamber. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to heat-exchangers, especially of the type where the one medium is constituted by a gas or by a vapor, and which comprises a plurality of elongate elements defining between themselves flow channels for the two media of the apparatus.
The main object of the invention is to provide a heat-exchanger simultaneously satisfying the requirements for high efficiency and for usefulness also in such connections where either the one medium contains substances which may have a corroding or eroding effect on the surface-extending means of the heat-exchanger, or one medium must be protected from direct contact with those means.
Another object of the invention is to provide a heat-exchanger the heat-exchanging elements of which shall be designed so as to permit low-cost manufacture in a continuous process which may, by way of example, comprise extrusion or pressing steps.
SUMMARY OF THE INVENTION
A heat-exchanger according to the invention satisfies all of the above-mentioned requirements. In addition thereto, according to several embodiments of the invention, a further advantage is that the elements may very conveniently be cleaned thanks to their smooth and continuous surfaces. The main characteristic of the invention is that the elements comprise cores made of a material with high heat-conducting capacity, said cores being, at least partially, surrounded by a coating or covering of another material. The coating or covering fulfills a dual purpose. On the one hand, it shields off the cores from direct contact with the one medium, and, on the other, it serves to retain the cores fixed in their positions.
According to one preferred embodiment of the invention each core is constituted by an integral piece, suitably shaped as an elongate strip. It may consist of copper or of any other suitable material of high heat-conducting capacity, whereas the covering may consist of a synthetic resin material.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments of the invention will be described below, reference being made to the accompanying, diagrammatic drawing in which:
FIG. 1 is a perspective view showing a portion of a heat-exchanging element according to a first embodiment;
FIG. 2 is a perspective view showing a portion of an element according to a second embodiment;
FIG. 3 is a partly sectional perspective view showing an element according to a third embodiment;
FIG. 3a shows on a larger scale a detail of the arrangement in FIG. 3;
FIG. 4 corresponds to FIG. 3 but discloses a fourth embodiment;
FIG. 4a corresponds to FIG. 3a but relates to FIG. 4;
FIG. 5 is a perspective view showing a portion of an element according to a fifth embodiment; and
FIGS. 6-12 each show a further embodiment of the invention.
DETAILED DESCRIPTION
Turning now to FIG. 1, reference numeral 1 designates the core of the element there shown. It consists of a material of high heat-conducting capacity, preferably copper. It is shaped like an elongate plate or strip and at both sides is connected to a semi-circular sheet 2 and 3, respectively. As appears from the drawing, core 1 may either be individual to each pair of sheets 2 and 3 or common to two or more such pairs. Sheets 2 and 3 define passage channels for the one heat-exchanging medium. Each such channel is by core 1 divided into two parallel branches. The just-mentioned medium will accordingly flow in heat-exchanging contact with core 1. It will also be in contact with the inner walls of sheets 2 and 3. The other medium will only be in direct contact with sheets 2 and 3, to wit: with the outer walls thereof. The other medium will, however, be in indirect contact also with core 1, because the portions of sheets 2 and 3 located between each circular passage for the first-mentioned medium may be looked upon as a covering for the flange-like portions of core 1 protruding outside the circumference of the flow channels of the first-mentioned medium. Numeral 4 designates such a portion of the element. Cores 1 may be secured to sheets 2 and 3 in any appropriate way, such as by welding, brazing, or clamping.
A number of elements, such as illustrated in FIG. 1, may be placed on top of each other forming a stack. It should also be noted that the profile of cores 1 does not need to be plane. By way of example, the profile may be curved, the radius of curvature being considerably greater than the radius of the circular flow channels. In such an element the individual channels will be disposed along a circular or helical line in the circumferential direction of the heat-exchanger.
Sheets 2 and 3 are generally made of a material which does not chemically or physically interact with the medium flowing in contact with their outer walls. As mentioned above, this means that either that medium or the cores 1, or both, are protected. A protection of the medium from direct contact with the copper cores 1 is of importance, e.g. in heat-exchangers used in food stuff or pharmaceutical industries. Conversely, a protection of the cores 1 is desired when the outer medium contains aggressive substances, e.g. is constituted by a gas or a vapor having a corroding or eroding influence on copper. Sheets 2 and 3 may consist of a metallic material or of a synthetic resin.
It should be noted that the portions of sheets 2 and 3 serving as a covering for the protruding parts of cores 1 simultaneously perform a second function, they retain cores 1 in their positions.
The profile of the element shown in FIG. 2 is that of a multi-pointed star. Its contour is defined by an outer sheet 5 having a plurality of folds each carrying a radially inwardly directed core 6 in the form of an elongate rectangular strip. The outer portion--according to the illustrated embodiment approximately half of the width--is accordingly at both sides covered by sheet 5, whereas the inner portions of the strips 6 project freely into the circular flow passage for the one medium. As should be understood, the folds of sheet 5 again perform a dual function, they retain strips 6 and they may serve as protection.
Also in the embodiment illustrated in FIG. 3 cores 6 consist of a plurality of elongate, rectangular metal strips. In this case, they are, however, arranged in parallel planes--rather than in the same plane as in FIG. 1 or in different planes as in FIG. 2. Sheets 8 and 9 have folds 7 surrounding the one edge portion of each strip 6 so as to serve as a covering and as a retaining means. Sheets 8 and 9 are stacked on top of each other, so that two different types of flow channels are formed. In the intermediate level there are formed channels 10, partly defined by the uncovered portions of strips 6. Below and above that level there are formed channels 11 and 12, respectively, each of which is omnilaterally defined by sheets 8 or 9, i.e. the medium flowing through these channels will only be in indirect contact with core strips 6.
The larger scale illustration in FIG. 3a shows one fold 7 surrounding a core strip 6. Numeral 15 designates embossments or depressed zones generated upon the fixation of the strip in the fold, e.g. by a roll-pressing operation. As should be understood, the corresponding possibility to manufacture the elements permits use of a process yielding a continuous coated or covered strip which is then divided into shorter pieces. In this connection it should be mentioned that the extent to which each strip 6 is coated or covered must be determined in each case with consideration being paid to the actual parameters, especially the relative thickness of the strips and the heat content of the heat-delivering medium.
FIG. 4 differs from FIG. 3 only in the way that strips 6 are completely coated or covered which is more clearly apparent from FIG. 4a.
FIG. 5 illustrates a modification of the embodiment shown in FIG. 4, the difference being that the strip has by cross-wise cuts been subdivided into a plurality of successive portions assuming mutually different angular positions. Also the end surfaces of these flap-like strip portions may be provided with a covering material so that the strip becomes omnilaterally coated or covering. The main advantage of this embodiment is that the relative displacement of the strip flaps generates turbulence, thereby improving the heat transfer.
In the embodiment shown in FIG. 6 strips 15 are of cruciform profile and omnilaterally surrounded by a covering material 16. Adjacent strips are interconnected via thin bridges 17 consisting of the covering material. At both sides of these bridges there is accordingly formed a groove which, as shown on the drawing, receives one end of a strip in an adjacent layer the strips of which are staggered in relation to the layer first referred to.
The sole difference between FIG. 7 and FIG. 6 is that at each of the four free ends of the cruciform strip covering material 16 has been given an L-shaped profile, so that there are formed grooves 18 for the interconnection of the strips.
According to FIG. 8, covering material 16 surrounds an elongate body 19 consisting of a metal wire grid. The covering material here consists of a synthetic resin and the covering, at each grid frame, has a depression 20 which may alternatively be a through aperture.
Also in FIG. 9 covering 16 consists of a resin material omnilaterally surrounding the core. However, in this case the core is discontinuous in the longitudinal direction of the core in that it consists of a number of embedded metal rods 21.
In FIG. 10 the principles of design illustrated in FIGS. 8 and 9 have been combined in the way that the fold-like portions of covering material 16 surround metal rods 21, whereas the arcuate portions surround a wire grid 19.
FIG. 11 shows a cross-section through a portion of an element having embedded metal rods 21. In this case the outer walls of the covering material follow the curvature of the rods.
Finally, FIG. 12 diagrammatically shows a portion of a complete heat-exchanger. The flow direction of the one medium has been marked with white arrows and that of the other medium with black arrows. The first-mentioned medium enters through a central tube 22 and the return flow, as seen in the radial direction, occurs through every second of the circular element layers. The other medium accordingly flows through the intermediate layers.
Finally, it should be noted that the term "heat-exchanger" as used here should be interpreted in a functional rather than a literal sense. It is intended to cover also such types of apparatus where the heat-exchanging function may not be the primary one. It should also be apparent from the description above that the invention is not limited to any special method as far as the application of the coating or covering material is concerned. In addition to extrusion and clamping processes, molding, milling and pressing, including powder-pressing, may be used. It is also possible to apply e.g. tin or a thermo-setting cement on the interface between the cores and the coating or covering, melting of the tin layer or curing of the cement, respectively, being accomplished by external heat-supply, e.g. by means of heated rollers used in a pressing operation. | The invention relates to heat-exchangers, especially of the type where the one medium is constituted by a gas or a vapor. It has a plurality of elongate elements which between themselves define the flow channels of the mediums. According to the invention, the elements comprise cores made of a material of high heat-conducting capacity. The cores are, at least partly, provided with a covering made of another material. The covering performs two functions; it keeps the cores fixed in their proper locations and they shield off the cores from direct contact with one of the two mediums. The covering may be metal or a synthetic resin. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a magnetic coil having three terminals for energization, a magnetic contactor using said magnetic coil, and a manufacturing method for said magnetic coil.
2. Description of the Background Art
FIG. 12 illustrates the arrangement of a magnetic coil and its peripheral elements in a conventional magnetic contactor which allows the magnetic coil to be energized via three terminal blocks. FIG. 13 illustrates a sectional view of the conventional magnetic contactor in FIG. 12. In these drawings, a magnetic coil 1, a coil frame 2 of the magnetic coil, a first terminal groove 2a formed in the coil frame 2, a second terminal groove 2b positioned opposite to the first terminal groove 2a, a winding 3 provided on the coil frame 2, a first coil terminal 4 press-fitted in the first terminal groove 2a of the coil frame 2, and a first terminal portion provided at the front end of the first coil terminal 4 and constituting an external wiring portion are shown. A start-of-winding tying portion 4b projects from the side face of the first coil terminal 4 and a second coil terminal 5 is disposed opposite to the first coil terminal 4 and press-fitted in the second terminal groove 2b of the coil frame 2. A second terminal portion 5a is provided at the front end of the second coil terminal 5, positioned opposite to the first terminal portion 4a, and constitutes an external wiring portion. An end-of-winding tying portion 5b projects from the side face of the second coil terminal 5, and a third terminal 5c is provided at the other end of the second coil terminal 5, positioned diagonally opposite to the first terminal portion 4a, and has a third terminal portion which constitutes an external wiring portion.
A case 6 accommodates the magnetic coil 1, supports the coil frame 2, and supports the terminal portions of the first coil terminal 4 and the second coil terminal 5. Panel installation holes 6a are disposed diagonally in the bottom surface of the case. A first terminal supporter 6b, a second terminal supporter 6c and a third terminal supporter 6d, support the terminal portions of the first terminal supporter 4 and the second terminal supporter 5. An E-shaped fixed core 7 has a central pole which is inserted into the magnetic coil 1 to support the coil frame 2 from the bottom surface. A movable core 8 is opposed to the fixed core 7 and is moved vertically by magnetic force generated by the magnetic coil 1. A contact support frame 9 is fixed to the movable core 8 and movable contacts 10 are switched on/off by the operation of the contact support frame 9. Fixed contacts 11 are opposed to the movable contacts 10, and a housing 12 secures the fixed contacts 11 and supports the contact support frame 9. A first terminal block 13 is constituted by the first terminal portion 4a and the first terminal supporter 6b. A second terminal block 14 is constituted by the second terminal portion 5b and the second terminal supporter 6c, and a third terminal block is constituted by the third terminal portion and the third terminal supporter 6d.
FIG. 14 illustrates a perspective view of the conventional magnetic coil showing the details of the coil frame 2 and the second coil terminal 5 in the arrangement of the magnetic contactor in FIG. 12, wherein a first press-fitting projection 21 is formed in a substantially L shape by cutting part of the second coil terminal 5. A second press-fitting projection 22 is opposed to the first press-fitting projection 21 and is formed in an oppositely substantially L shape to the first press-fitting projection 21. Catch projections 23 are formed by extrusion and a cross groove 24 is formed between the thin-wall plates of the coil frame 2 in the second terminal groove 2b of the coil frame 2. A first press-fitting groove 25 is formed perpendicularly to the cross groove 24. A second press-fitting groove 26 is opposed to the first press-fitting groove 25, and catch holes 27 are formed so as to pierce the upper thin-wall plate of the cross groove 24.
FIG. 15 is a perspective view showing the terminal block section of the conventional magnetic contactor disclosed in Japanese Laid-Open Patent Publication No. HEI 2-284325, wherein parts 21-26 correspond to those in the conventional art in FIG. 14.
The conventional magnetic contactor having three coil terminals is arranged as described above, and the first terminal block 13 and the second terminal block 14 are disposed on the power supply side of the magnetic contactor, spaced a sufficiently insulated distance away from the wiring to the power supply side of the fixed contacts 11, and wired unidirectionally. The third terminal block 15 is disposed diagonally opposite to the first terminal block 13 and is employed when wiring is employed on both the power supply side and load side of the magnetic contactor. When the magnetic contactor is wired, the first terminal block 13 and the second terminal block 14 can be wired, and at the same time, the first terminal block 13 and the third terminal block 15 can also be wired to allow a worker to select the terminal blocks according to the ease of wiring. When a thermal relay or the like has been fitted to the load side of the magnetic contactor, that terminal block which interferes with wiring can be avoided.
When the magnetic contactor according to the conventional art in FIG. 12 is installed to a panel, the magnetic contactor is fixed to the panel before the second terminal block 14 is wired since the panel installation hole 6a is arranged under the second terminal block 14, and is accessed with a screwdriver obliquely from the top to avoid the second terminal block 14.
The magnetic coil 1 is assembled with consideration given to winding workability. The first coil terminal 4 and the second coil terminal 5 integrated with the third coil terminal 5c are fitted to the coil frame 2, the start point of the winding 2 is soldered to the start-of-winding tying portion 4b, the winding is subsequently wound by a winder, and finally the winding end point is soldered to the end-of-winding tying portion 5b.
The first coil terminal 4 and the second coil terminal 5 are fitted to the coil frame 2 as shown in FIG. 14 (only terminal 5 is illustrated). The first press-fitting projection 21 and the second press-fitting projection 22 are inserted into the first press-fitting groove 25 and the second press-fitting groove 26, and the opposed inner faces of the first press-fitting projection 21 and the second press-fitting projection 22 are pressed against and fixed to the wall surfaces in the second terminal groove 2b. Further, the catch projections 23 and the catch holes 27 engage to prevent removal after press-fitting. When press-fitting fixture and engagement are executed simultaneously as shown in FIG. 15, the permanent engagement effect can be increased.
In the process of winding the magnetic coil 1 of said magnetic contactor, as shown in FIG. 17, a winder provided with a series of winding shafts, each of which is inserted into the center hole of a coil frame 2, is employed, and the winding shafts are rotated synchronously to rotate the coil frames 2, thereby winding the magnetic coils.
However, whereas the conventional magnetic coil 1 is improved in wiring performance because it has three terminals, projecting from both ends of the coil frame 2, the winding shaft-to-winding shaft distance which is equal to the value of [(the maximum radius 28)×2+(the clearance 29)], required for the winder, i.e., the dimensions of each winding station, must be increased as compared to that for generally used magnetic coils on which two coil terminals project in only one direction, whereby the winding work space is increased.
The magnetic contactor is desired to be compact to reduce the size of the control box in which the contactors are arranged and to make the control box more compact and slim.
However, since the winding of the conventional magnetic coil 1 is done after the fitting of the first coil terminal 4 and the second coil terminal 5 integrated with the third terminal 5c between the flanges of the coil frame 2, winding is not easily carried out. If the first coil terminal 4, the second coil terminal 5 and the third coil terminal 5c are located higher than the flanges of the coil frame 2, this poses a problem of electrical insulation between the terminal blocks and a main circuit or an auxiliary circuit located above them. Hence, the first coil terminal 4, the second coil terminal 5 and the third coil terminal 5c are projected in both directions and secured to the flange height positions of the coil frame 2.
For this reason, attempts to make the magnetic contactor more compact are limited by the insulation relationship between said coil terminal blocks and the main circuit or auxiliary circuit located above them, whereby the magnetic contactor cannot be made sufficiently compact.
Also, according to the usual form of magnetic contactor, e.g., when a thermal relay is fitted beforehand in close contact with the load side of the magnetic contactor, the terminal block located on the thermal relay side cannot be used due to interference with the thermal relay. In such a case, three terminal blocks are not required and a magnetic contactor having only two coil terminals projecting in only one direction is desirable in view of product costs and the like.
However, since the conventional magnetic coil 1 has three terminals projecting from both ends of the coil frame 2 for improvement in wiring performance, the third terminal will be wasted when said magnetic coil is employed as above.
Further, in the conventional magnetic contactor, the forces applied to the device during manufacture vary in direction, particularly with respect to the second terminal portion 5a, the third terminal portion and the end-of-winding tying portion 5b in the case of the second coil terminal 5, so that all portions cannot always be fixed sufficiently, whereby the outside of the first press-fitting projection 21 and the second press-fitting projection 22 are easily affected by vibration and wiring-time fastening.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome said disadvantages by providing a magnetic coil which does not incur an increase in winding space during winding work and which is compatible with specifications for either a magnetic coil having two coil terminals projecting in only one direction or a magnetic coil having three coil terminals.
Another object of the present invention is to provide a three-terminal type magnetic contactor using a magnetic coil which does not incur an increase in winding space and to provide a compact magnetic contactor of the three-terminal type.
A further object of the present invention is to provide a magnetic coil which is durable against vibration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view illustrating the arrangement of a magnetic coil and its peripheral elements in a magnetic contactor which embodies a first embodiment of the present invention.
FIG. 2 is a sectional view illustrating the overall arrangement of a magnetic contactor which embodies the first embodiment of the present invention.
FIG. 3 is a side view of the magnetic coil illustrating the method of fixing a coil terminal in the magnetic contactor in FIG. 1.
FIG. 4 is a perspective view of the magnetic coil illustrating the details of a coil frame and the coil terminal in the magnetic contactor in FIG. 1.
FIG. 5 is an exploded perspective partial view illustrating the arrangement of a magnetic coil in a magnetic contactor which embodies a second embodiment of the present invention.
FIG. 6 is an exploded perspective partial view illustrating the arrangement of a magnetic coil in a magnetic contactor which embodies a third embodiment of the present invention.
FIG. 7 is a sectional view illustrating an overall arrangement of the magnetic contactor which embodies the third embodiment of the present invention.
FIG. 8 is a sectional view from a position different from that of FIG. 7 of the magnetic contactor which embodies the third embodiment of the present invention.
FIG. 9 is a side view of the magnetic coil illustrating the method of fixing a coil terminal in the magnetic contactor in FIG. 6.
FIG. 10 is an exploded perspective view illustrating the arrangement of a magnetic coil in a magnetic contactor which embodies a fourth embodiment of the present invention.
FIG. 11 is an exploded perspective view illustrating the arrangement of a magnetic coil in a magnetic contactor which embodies a fifth embodiment of the present invention.
FIG. 12 is an exploded perspective view illustrating the arrangement of a magnetic coil in a magnetic contactor which embodies the conventional art.
FIG. 13 is a sectional view illustrating an overall arrangement of the magnetic contactor which embodies the conventional art.
FIG. 14 is an exploded perspective view of the magnetic coil illustrating the details of a coil frame and a coil terminal in the magnetic contactor in FIG. 12 which embodies the conventional art.
FIG. 15 is an exploded perspective view of the magnetic coil illustrating the details of a coil frame and a coil terminal in another magnetic contactor which embodies the conventional art.
FIGS. 16(a) and 16(b) show wiring work of the magnetic contactor in FIG. 1.
FIGS. 17(a) and 17(b) show wiring work of the magnetic contactor in FIG. 12.
FIG. 18 is a side view of the magnetic contactor provided with a thermal relay illustrating the space between the contactor and the thermal relay.
FIG. 19 is a plan view of the magnetic contactor provided with a thermal relay in FIG. 18.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention will now be described in accordance with FIGS. 1 to 4. FIG. 1 is a perspective view showing the arrangement of a magnetic coil in a magnetic contactor which embodies the first embodiment of the present invention, and FIG. 2 is a sectional view showing the overall arrangement of the magnetic contactor in FIG. 1. In these drawings, the numerals 7 to 12 indicate parts identical to those in the arrangement of the conventional magnetic contactor.
As shown in FIG. 1, a magnetic coil 101, a coil frame 102 of the magnetic coil, a first terminal groove 102a formed in the coil frame 102, a second terminal groove 102b formed opposite to the first terminal groove 102a, and terminal support frames 102c are formed to extend outwardly so as to be symmetrical with each other relative to the center of the coil frame 102. A winding 103 is provided on the coil frame 102, and a first coil terminal 104 is press-fitted in the first terminal groove 102a. A first terminal portion 104a is provided at the front end of the first coil terminal 104 and constitutes the external wiring portion of the first coil terminal 104.
As illustrated in FIG. 1, a start-of-winding tying portion 104b projects from the side face of the first coil terminal 104. A second coil terminal 105 is disposed opposite to the first coil terminal 104 and is press-fitted in the second terminal groove 102b. A second terminal portion 105a is provided at the front end of the second coil terminal 105 and is positioned opposite to the first terminal portion 104a and constitutes the external wiring portion of the second coil terminal 105.
An end-of-winding tying portion 105b projects from the side face of the second coil terminal 105. A terminal piece 105c provided at the other end of the second coil terminal 105 is bent in a substantially L shape and projects outwardly from the second terminal groove 102b of the coil frame 102 so that the terminal piece 105c can be connected with a plate spring 107c described later, and constitutes part of a third coil terminal as shown in FIG. 1. This terminal piece 105c is also designed such that the projection thereof is located in a cut-out formed at the corner of the coil frame 102.
A case 106 is formed to accommodate the magnetic coil 101, support the bottom surface of the coil frame 102, and cover the terminal support frames 102c on both side faces and bottom. Panel installation holes 106a are disposed diagonally in the bottom of the case 106, a first terminal supporter 106b supports the terminal support frames 102c, a second terminal supporter 106c is formed on the corner not having the panel installation hole 106a. A side wall groove 106d is formed in the side face of the case 106 along the second terminal supporter 106c, and an external wiring portion 107 is fitted into the second terminal supporter 106c, having a terminal surface at a height as shown in FIG. 2, which ranges in part below the plane of the top of the winding 103. External portion 107a is approximately as high as the top of the winding 103 of the magnetic coil 101, and constitutes the third coil terminal together with portion 107 and the terminal piece 105c, as illustrated in FIG. 1.
As shown in FIGS. 1 and 2, third terminal portion 107a is formed at the portion of the external wiring portion 107 fixed by the second terminal supporter 106c. A connection 107b extends from the third terminal portion 107a toward the inside of the case 106, and a plate spring 107c which has been formed in a substantially U shape, whose base is fixed to the connection 107b, and whose one side is bent at the front end into a V shape so as to return to the inside to provide an elastic effect. This plate spring 107c, which is supported by the side wall groove 106d constituting a container, is restricted by the inner wall of the side wall groove 106d so that the two sides come into contact with each other when the plate spring is supported. One leg runs along the inner wall of said side wall groove 106d as shown in FIG. 2, and its front end is contained to engage with the opening wall of the side wall groove 106d.
A first terminal block 108 is constituted by the first terminal portion 104a, the terminal support frame 102c and the first terminal supporter 106b. A second terminal block 109 is constituted by the second terminal portion 105b, the terminal support frame 102 and the second terminal supporter 106b. A third terminal block 110 is constituted by the third terminal portion 107a and the second terminal supporter 106c as depicted in FIG. 1.
FIG. 3 is a side view of the magnetic coil showing the coil frame 102, the first coil terminal 104 and the fixing method of the latter in the arrangement of the magnetic contactor in FIG. 1. FIG. 4 is a perspective view of the magnetic coil showing the details of the coil frame 102 and the first coil terminal 104. As shown in these drawings, a middle portion 121 is located in the middle of the first coil terminal 104. A terminal portion 122 extends from the middle portion 121 in the longitudinal direction with a step provided therebetween and front end which is tilted downwardly at the angle of A 123 relative to a plane parallel with the middle portion 121. A press-fitting projection 124 is formed such that one end opposite to the terminal portion 122 has been bent into a substantially L shape, with the middle portion 121 defined as one side, to form the sharp edge of angle B 125. A catch projection 126 is formed on the first coil terminal 104 by extrusion. A middle groove 127 is located in the middle of the first terminal groove 102a in the coil frame 102 and into which the middle portion 121 of the first coil terminal 104 is inserted. A terminal receiver 128 is formed in parallel with the middle groove 127 and is constituted only by a bottom surface. A press-fitting groove 129 is formed perpendicularly to the middle groove 127. A catch hole 130 is formed through the top surface of the middle groove 127 and the terminal receiver 128. A first support projection 131 is formed on the top surface of the middle groove 127, a second support projection 132 is formed on the bottom surface of the middle groove 127, and a third support projection 133 is formed on the press-fitting groove 129. Forces 134, 135, 136 work on the first coil terminal 104 when the first support projection 131 is used as a support 137. Force 134 works from the second support projection 132, force 135 works from the third support projection 133, and force 136 works from the terminal receiver 128. It is to be understood that said angle A 123 is designed to be 1° to 5° and angle B 125 is designed to be 85° to 89°.
In the magnetic contactor arranged as described above, the terminal support frames 102c and the first terminal supporter 106b which constitutes the first terminal block 108 and the second terminal block 109 are shared and disposed at the center of the magnetic contactor, whereby a screwdriver is passed beside the second terminal block 109 and the magnetic contactor is attached perpendicularly when screws are tightened into the panel installation holes 106a provided in the bottom surface of the case 106.
Also, when the magnetic coil 101 is manufactured, the winding work can be done simply by fitting to the coil frame 102 of the magnetic coil 101 the first coil terminal 104 and the second coil terminal 105 integrated with the terminal piece 105c constituting part of the third coil terminal. As shown in FIG. 16, each winding shaft of a winder is inserted into the center hole of a coil frame 102 of the magnetic coil 101, and the winding shafts are rotated synchronously to rotate the coil frames 102, thereby winding the magnetic coils 101. The winding shaft-to-winding shaft distance is equal to the value of [(the maximum radius 138)+(the partial radius 139 symmetrical with respect to the radius 138)+(the clearance 140)]. Whereas the magnetic coil is designed as a three-terminal type magnetic coil, winding can be carried out within a winding space equivalent to that of the generally used magnetic coil of which two coil terminals protrude in only one direction.
Also, when three terminal blocks are not required according to the use of the magnetic contactor, the magnetic coil 101 may be used in place of the generally used magnetic coil in which two coil terminals protrude in only one direction.
When the magnetic contactor is assembled, the terminal piece 105c formed on the second coil terminal 105 is connected in the moving direction of the movable core 8 with the plate spring 107c constituting part of the external wiring portion 107, by fixing the external wiring portion 107 constituting part of the third coil terminal beforehand to the case 106 and placing the magnetic coil 101 (manufactured separately) into the case 106. The terminal piece 105c integrated with the second coil terminal 105 is inserted into the center of the substantially U-shaped plate spring 107c and the plate spring 107c presses the terminal piece 105c by its own elasticity to hold the terminal piece therein.
Hence, since the external wiring portion 107 of the third coil terminal is partially assembled independently of the magnetic coil 101 and is connected with the terminal piece 105c in the final overall assembly, the location of the third terminal block 110 can be determined independently of the magnetic coil 101, and therefore the third terminal block can be disposed at a considerably lower position so as to satisfy the insulation relationship between the terminal block of the main circuit or the auxiliary circuit located above the third coil terminal block, whereby the magnetic contactor can be reduced in size.
The terminal piece 105c is connected with the plate spring 107c, which is formed in a U shape, and whose base is fixed to the connection 107b. One leg on one side is bent in a V shape to return to the inside at the front end to provide an elastic effect, which is supported in compression such that the two legs on either side make contact with each other in the side wall groove 106d, with one leg running along the inner wall of said side wall groove 106d as shown in FIG. 2. The front end is contained to engage with the opening wall of side wall groove 106d, whereby the terminal piece 105c cannot be inadvertently inserted between the plate spring 107c and the inner wall of the side wall groove 106d and both are electrically connected with excellent contact pressure.
Also, when the plate spring 107c, is put into the side wall groove 106d, the plate spring 107c can be positioned within the side wall groove 106d with high accuracy.
Since the terminal piece 105c constituting part of the third coil terminal is designed to be connected with the plate spring 107 which is biased in a direction orthogonal to the operation of the movable core 8, the connection reliability is high.
The third terminal consisting of the terminal piece 105c and the external wiring portion 107 is provided on the load side of the magnetic contactor, i.e., on the side where a thermal relay is fitted in close contact, whereby when a thermal relay is fitted in close contact beforehand, it is possible to remove beforehand the external wiring portion 107 which becomes unusable at that time.
The method of fixing the first coil terminal 104 will now be described. The terminal portion 122 lowered at the angle of A 123 relative to the middle portion 121 is pushed up by the terminal receiver 128 as soon as the first coil terminal 104 is inserted into the first terminal groove 102a. Also, the press-fitting projection 124 formed at the angle of B 125 relative to the middle portion 121 is bent upward along the press-fitting groove 129 formed perpendicularly. This causes the force 135 working from the third support projection 133 and the force 136 working from the terminal receiver 128 to be applied to the first coil terminal 104. These forces balance with each other with respect to the support 137 in terms of moment to fix the first coil terminal. Also, the middle portion 121 is supplementarily secured by the force 134 working from the second support projection 132 to make the start-of-winding tying portion 104b more stable. The first coil terminal 104 is held by the engagement of the catch projection 126, which is formed on the surface to which pressure is imposed, and the catch hole 130 to provide firm engagement and does not allow the first coil terminal to be easily removed.
Though not described here, the second coil terminal 105 is also fixed in a similar manner, and further, the terminal piece 105c bent in a substantially L shape is bent upward at the same sharp angle as the press-fitting projection 124 to secure the second coil terminal.
A second embodiment of the present invention will now be described in accordance with FIG. 5, which is an exploded perspective view showing the arrangement of a magnetic coil in a magnetic contactor which embodies the second embodiment. As illustrated in FIG. 5, there is a magnetic coil 201, a coil frame 202 of the magnetic coil, a second terminal groove 202a formed in the coil frame 202 and a second coil terminal 203 press-fitted into the second terminal groove 202. A terminal piece 203a is formed by protruding one end of the second coil terminal 203 outwardly in a substantially L shape and constitutes a third coil terminal along with an external wiring portion mentioned later. This terminal piece 203a is also designed such that its projection end is located in a cut-out formed at the corner of the coil frame 202. A case 204 accommodates the magnetic coil 201 and supports the coil frame 202. A second terminal supporter 204a is formed at the corner of the case 204, and an external wiring portion 205 is press-fitted into the second terminal 204a and constitutes the third coil terminal together with the terminal piece 203a.
A third terminal portion 205a is formed at the portion of the external wiring portion 205 fixed by the second terminal supporter 204a. A connection 205b extends from the third terminal portion 205a toward the inside of the case 204. A plate spring 205c has been bent into a V shape to provide an elastic effect and has one end fixed to the connection 205b. A third terminal block 206 is constituted by the third terminal portion 205a and the second terminal supporter 204c. The parts not shown are identical to those in Embodiment 1 in FIG. 1.
In the magnetic contactor arranged as described above, after the second coil terminal 203 integrated with the terminal piece 203a constituting part of the third coil terminal is fitted to the coil frame 202 as in Embodiment 1 in FIG. 1, winding is done, and subsequently the magnetic coil 201 is assembled into the case 204 which has been fitted beforehand with the external wiring portion 205 of the third coil terminal. At this time, the external wiring portion 205 of the third coil terminal is connected with the terminal piece 203a via the plate spring 205c. Also, the plate spring 205c is pressed elastically by the pressure of assembling the magnetic coil 201 to completely hold the connection with the terminal piece 203a. The present embodiment also provides the same effects as Embodiment 1.
A third embodiment of the present invention will now be described as shown in FIGS. 6-9. In these drawings, the numerals 7 to 12 indicate parts identical to those in the arrangement of the conventional magnetic contactor as shown in FIGS. 12-13. The third embodiment has a magnetic coil 301, a coil frame 302 of the magnetic coil, a first terminal groove 302a formed in the coil frame 302, a second terminal groove 302b formed opposite to the first terminal groove 302a, terminal support frames 302c which extend outwardly so as to be symmetrical with each other relative to the center of the coil frame 302 and integrated with each other at the front end. A fitting projection 302d protrudes from an upper thin plate of the coil frame 302. A fitting groove 302e is opposed to the fitting projection 302d and formed on a block projecting from the coil frame 302. A winding 303 is provided on the coil frame 302 and a first coil terminal 304 is press-fitted in the first terminal groove 302a. A first terminal portion 304a is provided at the front end of the first coil terminal 304 and constitutes the external wiring portion of the first coil terminal 304.
A start-of-winding tying portion 304b projects from the side face of the first coil terminal 304. A second coil terminal 305 is disposed opposite to the first coil terminal 304 and is press-fitted in the second terminal groove 302b. A second terminal portion 305a is provided at the front end of the second coil terminal 305 and is positioned opposite to the first terminal portion 304a, and constitutes the external wiring portion of the second coil terminal 305. An end-of-winding tying portion 305b projects from the side face of the second coil terminal 305, and a terminal piece 305c is provided at the other end of the second coil terminal 305, projecting outwardly from the second terminal groove 302b of the coil frame 302 so that it can be connected with a plate spring 309 described later, and constitutes part of a third coil terminal. This terminal piece 305c is also designed such that the projection end thereof is located in a cut-out formed at the corner of the coil frame 302.
A case 306 is formed to accommodate the magnetic coil 301, support the bottom surface of the coil frame 302, and cover the terminal support frames 302c at both side faces and bottom. Panel installation holes 306a are disposed diagonally in the bottom of the case 306. A first terminal supporter supports the terminal support frames 302c and a second terminal supporter 306c is formed on the corner not having the panel installation hole 306a. An external wiring portion 307 is press-fitted into the second terminal supporter 306c and has a terminal surface at a height within the range in which the winding 303 of the magnetic coil 301 is wound, and constitutes the third coil terminal along with a joint mentioned later and the terminal piece 305c.
A third terminal portion 307a is formed at the portion of the external wiring portion 307 fixed by the second terminal supporter 306c. An inserting portion 307b is bent upward into a substantially L shape from the third terminal portion 307a and chamfered at the front end. A joint frame 308 fitted onto the fitting projection 302d and into the fitting groove 302e of the coil frame 302 is bridged across the flanges of the coil frame 302 and has grooves where a plate spring 309c, mentioned later, both sides of the terminal piece 305c, the fitting projection 302d and the inserting portion 307b formed on the external wiring portion 307 are inserted. A plate spring 309 is fitted along a groove formed in the joint frame 308 so as to be totally covered by said joint frame 308, and is bent into a substantially L shape to make contact with both the terminal piece 305c of the third coil terminal and the inserting portion 307b of the external wiring portion 307 Contact portions are bent into a V shape to provide an elastic effect. The plate spring 309 constitutes a joint together with the joint frame 308. The portion brought into contact with the terminal piece 305c of the third coil terminal is bent such that the elastic force works in the same direction as the moving direction of the movable core, and the portion brought into contact with the inserting portion 307b of the external wiring portion 307 is bent such that the elastic force works in the direction orthogonal to the moving direction of the movable core.
A first terminal block 310 is constituted by the first terminal portion 304a, the terminal support frame 302c and the first terminal supporter 306b. A second terminal block 311 is constituted by the second terminal portion 305b, the terminal support frame 302c and the first terminal supporter 306b. A third terminal block 312 is constituted by the third terminal portion 307a and the second terminal supporter 306c.
As shown in FIG. 9, a terminal portion 321 is formed at one end of the second coil terminal 305, and a cross portion 322 extends from the terminal portion 321 in the longitudinal direction with a step provided therebetween and is formed at the other end of the second coil terminal 305. A press-fitting projection 323 is designed such that the center of the second coil terminal 305 has been cut and bent into a substantially L shape to form a sharp angle of C 324 with a plane parallel with the cross portion 322. A catch projection 325 is formed at the second coil terminal 305 by extrusion. A cross groove 326 forms substantially half of the second terminal groove 302b in the coil frame 302, into which the cross portion 322 of the second coil terminal 305 is inserted. A terminal receiver 327 is formed in parallel with the cross groove 326 and is constituted only by a bottom surface.
A press-fitting groove 328 is formed perpendicular to a step provided between itself and the cross groove 326. A catch hole 329 is formed through the top surface of the cross groove 326 and the terminal receiver 327. A first support projection 330 is formed on a portion of a surface perpendicular to the press-fitting groove 328 and adjacent the press-fitting groove 328. A second support projection 331 is formed on the top surface of the cross groove 326 and a third support projection 326 is formed on the press-fitting groove 328. Forces 333, 334, 335 work on the second coil terminal 305 when the first support projection 330 is used as a support 336. A force 333 works from the second support projection 331, another force 334 works from the third support projection 332, and still another force 335 works from the terminal receiver 327. It is to be understood that said angle C 324 is designed to be between 85° to 90°.
The magnetic contactor arranged as described above is assembled in the following manner. Namely, the first coil terminal 304 and the second coil terminal 305 integrated with the terminal piece 305c constituting part of the third coil terminal are fitted to the coil frame 302 and winding work is carried out to manufacture the magnetic coil 301 beforehand. Then, the joint frame 308 accommodating the plate spring 309 is fitted into the coil frame 302 of said manufactured magnetic coil 301 to connect the terminal piece 305c and the plate spring 309. Specifically, the fitting projection 302d of the coil frame 302 is inserted into the groove of the joint frame 308, both sides of the terminal piece 305c are inserted into the groove of the joint frame 308 so as to be located under the fitting projection 302d, and the engagement portion formed at the bottom end of the joint frame 308 is fitted into the fitting groove 302e. When the joint frame 308 is fitted to the coil frame 302 as described above, the joint frame 308 is bridged across the flanges of the coil frame 302 to mechanically reinforce the coil frame 302, whereby the coil frame 302 can be prevented from being deformed and/or damaged if mechanical stress is applied to the coil frame 302.
Also, both sides of the terminal piece 305c are inserted into the groove of the joint frame 308 to mechanically position said terminal piece 305c and the plate spring 309 bent to work elastic force in the same direction as the moving direction of the movable core 8 is positioned under the terminal piece 305c by the groove of the joint frame 308, whereby the fitting projection 302d of the coil frame 302 is located above the plate spring 309 and also the plate spring 309 and the terminal piece 305c make a very reliable electrical connection. Also, at this time, since the fitting projection 302d of the coil frame 302 is engaged with the groove of the joint frame 308, the electrical connection of the plate spring 309 and the terminal piece 305c is maintained even if subjected to mechanical vibration.
When the fitting of the joint frame 308 is complete, the magnetic coil 301 is contained in the case 306. When the inserting portion 307b of the external wiring portion 307 fixed beforehand to the case 306 is inserted into the groove of the joint frame 308 in the moving direction of the movable core 8, the plate spring 309 presses the inserting portion 307b of the external wiring portion 307 by its own elasticity, which works in the direction orthogonal to the moving direction of the movable core 8, to connect the terminal piece 305c and the external wiring portion 307 via the plate spring 309. At this time, the inserting portion 307b of the external wiring portion 307 constituting part of the third coil terminal is designed to be connected with the plate spring 309 which works in the direction orthogonal to the movement of the movable core 8, ensuring high connection reliability.
Finally, when the housing 12 where contacts and the like have been assembled is fitted, the assembly of the magnetic contactor is complete. At this time, since the housing 12 is fitted such that the external wiring portion 307 is pressed by the opening end face of the housing 12 via the connection portion of the inserting portion 307b of the external wiring portion 307 and the plate spring 309, the mechanical fixture of the external wiring portion 307 is firm, and in addition, if the external wiring portion 307 is fixed below the opening end face of the case 306, part of the housing 12 need not be extended because of that pressure, whereby the shape of the housing 12 is simplified.
Also, in the magnetic contactor designed as described above, the terminal piece 305c and the external wiring portion 307 are connected by the plate spring 309 which is practically covered with the joint frame 308, whereby if the external wiring portion 307 constituting part of the third coil terminal is adjacent to the terminal block of a main or auxiliary circuit located above as shown in FIG. 8, the insulation relationship between them can be fully satisfied and the magnetic contactor can be made more compact than those in Embodiment 1 or 2. It is to be understood that the present embodiment produces identical effects to those of Embodiment 1.
Also, the present embodiment, designed such that the joint is located on the third coil terminal side in the above description, may be arranged such that said joint is employed on the first and second coil terminal side when the manufactured magnetic coil will not be used as a general magnetic coil from which only two terminal coils project only in one direction.
The method of fixing the second coil terminal 305 will now be described. First, the terminal portion 321 and the cross portion 322 formed in parallel with each other can be inserted comparatively easily into to the terminal receiver 327 and the cross groove 326 which are formed similarly in parallel with each other. At this time, the press-fitting projection 323 is easily inserted into the press-fitting groove 328 but when the press-fitting projection 323 rides on the third support projection 324, the press-fitting projection 323 formed to have the sharp angle of C 324 is bent upward perpendicularly and is imparted the force 334 which works from the third support projection 323. Since the second coil terminal 305 attempts to return to its original shape by its own elasticity, a moment is generated using the first support projection 330 as the support 336 and the second coil terminal 305 is given counterforces in the form of the force 333 which works from the second support projection 331 and the force 335 which works from the terminal receiver 327. The above balance of forces causes the second coil terminal 305 to be fixed inside the second terminal groove 302b of the coil frame 302. Also, since the second coil terminal 305 is held by the engagement of the catch projection 325, which is formed on the surface to which pressure is applied and the catch hole 329, the engagement is so firm that the second coil terminal 305 cannot easily be removed. The terminal portion 321, the end-of-winding portion 305b and the terminal piece 305c are directly fixed immediately nearby, whereby they are stably fitted.
A fourth embodiment of the present invention will now be described in accordance with FIG. 10. As illustrated in FIG. 10, there exists a magnetic coil 401, and a coil frame 402 of the magnetic coil. A first terminal groove 402a is formed in the coil frame 402 and a second terminal groove 402b is formed opposite to the first terminal groove 402a. Union projections 402c are formed above the first terminal groove 402a and the second terminal groove 402b and have symmetrically sufficiently spaced rails. Union windows 402d are cut along the rails between the rails of the union projections 402c. A terminal support frame 403 having two arm-shaped hollow portions formed symmetrically is shown. Union grooves 403a are formed in the two front ends of the terminal support frame 403 and a first external wiring portion 404 is press-fitted into the terminal support frame 403 and constitutes part of a first coil terminal together with a first terminal piece 406 mentioned later. A first terminal portion 404a is provided at the front end of the first external wiring portion 404 and a first connection 404b extends from the first terminal portion 404a with a step provided therebetween. A first plate spring 404c is fixed to the first connection 404b. A second external wiring portion 405 disposed opposite to the first external wiring portion 404 press-fitted into the terminal support frame 403, and constitutes part of a second coil terminal along with a second terminal piece 407 described later. A second terminal portion 405a is provided at the front end of the second wiring portion 405. A second connection 405b extends from the second terminal portion 405a with a step provided therebetween. A second plate spring 405c is fixed to the second connection 405b. A first terminal piece 406 is press-fitted into the first terminal groove 402a of the coil frame 402. A start-of-winding tying portion 406a projects from the side face of the first terminal piece 406. A first connection portion 406b is located at one end of the first terminal piece 406. A second terminal piece 407 is press-fitted into the second terminal groove 402b of the coil frame 402. A third terminal 407a is provided at the front end of the second terminal piece 407. An end-of-winding tying portion 407b projects from the side face of the second terminal piece 407. A second connection portion 407c is located at the other end of the second terminal piece 407. A case 408 is formed to accommodate the magnetic coil 401, support the bottom surface of the coil frame 402 and also the terminal support frame 403, and cover the terminal support frame 403 an both side faces and bottom. Panel installation holes 408a are disposed diagonally in the bottom of the case 408. A first terminal supporter 408b supports the terminal support frame 403 and a second terminal supporter 408c is formed on the corner not having the panel installation hole 408a. A first terminal block 409 is constituted by the first terminal portion 404a, the terminal support frame 403 and the first terminal supporter 408b. A second terminal block 410 is constituted by the second terminal portion 405b, the terminal support frame 403 and the first terminal supporter 408b. A third terminal block 411 is constituted by the third terminal 407a and the second terminal supporter 408c. It is to be understood that the first terminal piece 406 and the second terminal piece 407 are designed to be practically contained in the flanges of the coil frame 402.
When the magnetic coil 401 is assembled, the first terminal piece 406 and the second terminal piece 407 are first fitted to the coil frame 402 and winding is completed. Then, the coil frame 402 and the terminal support frame 403 into which the first external wiring portion 404 and the second external wiring portion 405 have been press-fitted beforehand are engaged by the union projections 402c and the union grooves 403. The first terminal piece 406 and the first external wiring portion 404 are connected by the first plate spring 404c and the second terminal piece 407 and the second external wiring portion 405 are connected by the second plate spring 405c through the union windows 402d. After the coil frame 402 and the terminal support frame 403 are put into the case 408, the case 408 supports them so that they are fixed as a stable union. The first external wiring portion 404 and the second external wiring portion 405 are partially assembled independently of the magnetic coil 401, and are connected after the winding work, whereby the locations of the first terminal block 409 and the second terminal block 410 are determined independently of the magnetic coil 401. The present embodiment has the same effects as Embodiment 1.
A fifth embodiment of the present invention will now be described in accordance with FIG. 11. As illustrated in FIG. 11, there is a magnetic coil 501, and a coil frame 502 of the magnetic coil. A first terminal groove 502a is formed in the coil frame 502 and a second terminal groove 502b is formed opposite to the first terminal groove 502a. A first external wiring portion 503 is formed in a substantially L shape and constitutes a first coil terminal together with a first terminal piece 505 mentioned later. A first terminal portion 503 is provided at the front end of the first external wiring portion 503. A first connection 503b extends from the first terminal portion 503a with the substantially L-shaped portion provided therebetween. A first plate spring 503c is fixed to the first connection 503b. A second external wiring portion 504 is formed in a substantially U shape, of which both ends are bent to form a substantially L shape and constitutes a second coil terminal along with a second terminal piece 506 described later. A second terminal portion 504a is provided at one end of the second wiring portion 504. A third terminal 504b is provided at the other end of the second external wiring portion 504. A second connection 504c extends from the second terminal portion 504a with the substantially L-shaped portion provided therebetween. A second plate spring 504d is fixed to the second connection 504c. A first terminal piece 505 is press-fitted into the first terminal groove 502a of the coil frame 502. A start-of-winding tying portion 505a projects from the side face of the first terminal piece 505. A first connection portion 505b is formed opposite the first plate spring 503c. A second terminal piece 506 is press-fitted into the second terminal groove 502b of the coil frame 502. An end-of-winding tying portion 506a projects from the side face of the second terminal piece 506. A second connection portion 506b is formed opposite the second plate spring 504d. A case 507 is formed to accommodate the magnetic coil 501 and support the bottom surface of the coil frame 502. Panel installation holes 507a are disposed diagonally in the bottom of the case 507. A first terminal supporter 507b secures the first terminal portion 503a and the second terminal portion 504a. A second terminal supporter 507c secures the third terminal portion 504b. A first terminal block 508 is constituted by the first terminal portion 503a, the coil frame 502 and the first terminal supporter 507b. A second terminal block 509 is constituted by the second terminal portion 504a, the coil frame 502 and the first terminal supporter 507b. A third terminal block 510 is constituted by the third terminal 504b and the second terminal supporter 507c. It is to be understood that the first terminal piece 505 and the second terminal piece 506 are designed to be practically contained in the flanges of the coil frame 502.
When the magnetic coil 501 is assembled, the first terminal piece 505 and the second terminal piece 506 are first fitted to the coil frame 502 and winding is completed. The first external wiring portion 503 and the second external wiring portion 504 integrated with the third coil terminal 504b are press-fitted directly into the case 507 and secured at a position where the magnetic coil 501 is avoided. As soon as the magnetic coil 501 is contained in the case 507, the first plate spring 503c and the second plate spring 504c disposed symmetrically with each other on the side faces of the case 507 and fixed facing the inside of the case 507 are connected with the first terminal piece 505 and the second terminal piece 506. The first external wiring portion 503 and the second external wiring portion 504 are partially assembled independently of the magnetic coil 501 and are connected after the winding procedure, whereby the locations of all of the terminal blocks are determined independently of the magnetic coil 501.
It will be apparent that the invention, as described above, achieves a magnetic coil which does not increase the winding space needed and which is compatible with the specification of either a magnetic coil from which two coil terminals protrude in one direction and a magnetic coil having three coil terminals.
The magnetic contactor allows a third coil terminal block to be disposed in considerably lower position in order to satisfy the insulation relationship with the terminal block of a main or auxiliary circuit which is located above, whereby the size of the magnetic contactor can be reduced even though it is of the three-terminal type.
It will also be apparent that the invention achieves a magnetic contactor which ensures high reliability of the connection between the terminal piece of a third coil terminal and an external wiring portion, in addition to the above effects.
It will also be apparent that the invention achieves a magnetic contactor in which the terminal piece cannot be inserted between an elastic portion and the inner wall of a container, and which ensures high reliability connection between the terminal piece of a third coil terminal and an external wiring portion and allows the elastic portion to be contained in the container with high accuracy, in addition to the above effects.
It will also be apparent that the invention achieves a magnetic contactor which maintains the electrical connection between a conductive piece and a terminal piece extremely reliably even if subjected to mechanical vibration.
It will also be apparent that the invention achieves a magnetic contactor which can prevent a coil frame from being deformed and/or damaged if mechanical stress is applied to the coil frame.
It will also be apparent that the invention achieves a magnetic contactor in which the mechanical fixture of an external wiring portion is firm, and if the external wiring portion is located below the opening end face of a case, part of the housing need not be extended and the housing shape is simplified.
It will also be apparent that the invention achieves a magnetic contactor in which the external wiring portion of a third coil terminal that cannot be used when a thermal relay is fitted beforehand in close contact can be removed beforehand from the magnetic contactor.
It will also be apparent that the invention achieves a magnetic contactor in which the winding space of a magnetic coil is equivalent to that of a magnetic coil where only two coil terminals are used, and a method of manufacturing a magnetic coil which provides a magnetic coil having terminals durable against mechanical vibration. | A magnetic coil, a magnetic contactor using the magnetic coil and a method for manufacturing the magnetic coil are disclosed wherein the magnetic coil does not need increased winding space and can be configured as having two coil terminals protruding in only one direction or as having three coil terminals. A three terminal-type magnetic contactor which uses the magnetic coil does not require an increased amount of space for the winding process, and the size of the three terminal version is reduced while still meeting insulation requirements. The magnetic coil maintains reliable electrical connection even when subjected to mechanical vibration. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to co-pending U.S. patent application Ser. No. 09/227,502 entitled Methods And Apparatus For Data Bus Arbitration filed on Jan. 6, 1999, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to synchronous dynamic random access memory (SDRAM) technology and more particularly, to techniques for optimizing the operation of a SDRAM for variable length data transfers.
2. Description of the Related Art
Dynamic random access memory (DRAM) is used to provide a number of different functions in computers including: “scratch pad” memory and video frame buffers. A synchronous DRAM or SDRAM is designed to deliver bursts of data at very high speed using automatic addressing, multiple page interleaving, and a synchronous (or clocked) interface.
FIG. 1 is a block diagram illustrating a SDRAM 10 of the prior art. SDRAM 10 includes a control logic unit 12 that receives address, row address select (RAS), column address select (CAS), write enable (WE), and data input/output mask (DQM) assertions which control the operation of the SDRAM. Control logic unit 12 uses the assertions to control a number of memory banks (“banks”) 14 , which are labeled A-N. Banks 14 receive and transmit data through an output requestor 16 and an input requester 18 to a data bus 20 .
FIG. 2A is a flow chart of a prior art method 22 of operating a SDRAM controller in a “fixed length” mode. Method 22 begins at an operation 24 , where the SDRAM is programmed into the most common mode, the fixed length mode. A fixed length of transfer of 1, 2, 4, or 8 data phases is chosen during the mode register select (MRS) cycle. Then, an operation 26 optimizes the burst transfers for same bank transactions which is ideal for computer applications because computers process data in bursts that are often sequential and defined at a fixed length.
Optimization may include a SDRAM feature called auto refresh. Because SDRAM memory cells are capacitive, the charge they contain dissipates with time. As the charge is lost, so is the data in the memory cells. To prevent this from happening, SDRAMs must be refreshed by restoring the charge on the individual memory cells periodically. In addition, the SDRAM may use a feature called auto precharge, which allows the memory chip's circuitry to close a page automatically at the end of a burst. Auto precharge can be used because the burst transfers are of a fixed length, and it is known when the transfers will terminate.
FIG. 2B is a flow chart of a prior art method 28 of operating a SDRAM controller in “variable length” mode. Variable length mode is required in applications that do not use the 1, 2, 4, or 8 data phase transaction set available from the fixed mode. The method 28 begins with an operation 30 where the SDRAM is programmed in variable length mode. The variable length mode of the SDRAM, which is also known as full page length mode, is used to accommodate applications with long streams of data, such as those that are present in DMA and video. After the SDRAM is programmed, an operation 32 optimizes the burst transfers for multiple bank transactions.
FIG. 2C is a flow chart of a alternative prior art method 34 of operating a SDRAM controller in a variable length mode. The method 34 begins at operation 30 where the SDRAM is programmed in variable length mode. Then, an operation 36 optimizes the burst transfers for same bank transactions.
While the above methods 28 and 34 arc adequately able to handle applications such as using DMA for a frame buffer or streaming data off of a disk drive system and buffering data into RAM, they are inefficient for applications where the length of the data bursts varies from short to long lengths. When the bursts vary between lengths, it becomes very difficult for the SDRAM to determine when to terminate the transaction.
Furthermore, methods 28 and 34 are also inefficient for applications that require the SDRAM to service multiple requestors. In such scenarios, prior art methods would only be able to handle one request at a time in same bank situations, forcing the other requests to wait, even as the SDRAM experiences idle cycles. In view of the foregoing, it is desirable to have methods and an apparatus that is able to optimizes the burst transfer lengths to requesters' different characteristics, and at the same time allowing the data bus to change to a different transaction with minimal idle time on the bus.
SUMMARY OF THE INVENTION
The present invention fills these needs by providing methods and an apparatus providing techniques for optimizing the operation of a SDRAM for variable length data transfers. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device or a method. Several inventive embodiments of the present invention are described below.
Briefly, a SDRAM system includes a SDRAM having multiple banks of memory, a plurality of bank state machines associated the multiple banks of memory of the SDRAM, and a data control state machine. The data state machine is responsive to a memory request for a variable length data transfer with the SDRAM and as well as the bank state machines. The data control state machine determines the current state of a first bank of memory of the SDRAM. The current state may be either a read in progress, a write in progress, or idle. The data control state machine then handles the memory request with a different bank of memory RAM depending upon the current state of the first bank of memory.
In another embodiment of the present invention, a method for processing variable length data transfers in a SDRAM is disclosed. The method includes receiving a memory request for a variable length data transfer with a SDRAM having multiple banks of memory. A current state of a currently used bank of memory of the SDRAM is selected from the states of read in progress, write in progress, and idle. The memory request to a selected bank of memory is chosen and handled depending upon the current state of the SDRAM.
An advantage of the present invention is that it provides for efficient use of the memory banks of a SDRAM for multiple variable length memory requests. More specifically, the present invention allows the processing of multiple variable length memory requests by determining when each memory bank access will terminate. The present invention then maximizes use and reduces idle time of the SDRAM memory banks by identifying a window of opportunity at which it is possible to overlap a second transaction with the current transaction and processing the second transaction before the current transaction terminates.
Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be readily understood by the following, detailed description in conjunction with the accompanying drawings. To facilitate this description, like reference numerals designate like structural elements.
FIG. 1 is a block diagram illustrating a SDRAM controller.
FIG. 2A is a flow chart of a prior art method of operating a SDRAM controller in the fixed length mode.
FIG. 2B is a flow chart of a prior art method of operating a SDRAM controller in a variable length mode.
FIG. 2C is a flow chart of a alternative prior art method of operating a SDRAM controller in variable length mode.
FIG. 3 illustrates a SDRAM controller in accordance with one embodiment of the present invention and an associated N-Bank SDRAM.
FIG. 4 illustrates a method of processing requests for memory access in accordance with one embodiment of the present invention.
FIG. 5 is a flow chart of a method of processing a request for memory access when there is a read in progress on the data bus.
FIG. 6 is a flow chart of a method of processing a request for memory access when there is a write in progress on the data bus.
FIG. 7 is a flow chart of a method of processing a request for memory access when the data bus is idle.
FIG. 8 is a state diagram of BankA state machine of FIG. 3 .
FIG. 9 is a state diagram of BankB-N state machine of FIG. 3 .
FIG. 10 is a state diagram of data control state machines of FIG. 3 after receiving a write command.
FIG. 11 is a state diagram of data control state machines of FIG. 3 after receiving a read command.
FIG. 12 is a timing diagram of the state machines during consecutive read commands with next transfer termination.
FIG. 13 is a timing diagram of the state machines during consecutive write commands with next transfer termination.
FIG. 14 is a timing diagram of the state machines during a read, a write and then another read command with next transfer termination.
FIG. 15 is a timing diagram of the state machines during three reads with precharge termination.
FIGS. 16-18 are timing diagrams of the state machines during various other operations with precharge termination.
FIGS. 19-20 are timing diagrams for processor read and processor write transactions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known structures and process operations have not been described in detail in order not to unnecessarily obscure the present invention.
FIGS. 1 and 2 A- 2 C were described with reference to the prior art. FIG. 3 illustrates a SDRAM controller 38 in accordance with one embodiment of the present invention. SDRAM controller 38 includes an arbiter 40 , a BankA state machine (“master state machine”) 42 , a number of BankB . . . BankN state machines (“common state machines”) 44 , a data control state machine 46 , a control/status router module 48 , an initialization sequencer 49 , an address generator 50 , a refresh module 51 , a control signal generator 52 , and a data buffer module 54 .
SDRAM controller 38 communicates with N-Bank SDRAM 55 , which stores and retrieves data for an infinite number of banks for use by SDRAM controller 38 and the devices to which SDRAM controller 38 is attached. Arbiter 40 receives inputs from the external req and bankAddr busses, from master state machine 42 , common state machines 44 , and data control state machines 46 . Using the input information, arbiter 40 then arbitrates between the requestors, and after establishing the priority of requestors for access to N-Bank SDRAM 55 , outputs to the external aBcntEn bus, master state machine 42 , common state machines 44 , and data control state machines 46 .
Master state machine 42 and common state machines 44 receive input from control/status router module 48 , initialization sequencer 49 , refresh module 51 , and data control state machines 46 in addition to being in communication with arbiter 40 and each other. Master state machine 42 and common state machines 44 are associated with the corresponding memory banks in N-Bank SDRAM 55 and function to provide the appropriate sequence of signal change timing indicators to manage the access to the corresponding memory banks in N-Bank SDRAM 55 .
Data control state machines 46 receive inputs from the external bCnt bus, control/status router module 48 , the arbiter 40 , master state machine 42 , and common state machines 44 , and produces outputs to the external dEn bus, arbiter 40 , master state machine 42 , common state machines 44 , control signal generator 52 , and data buffer module 54 . Data control state machines 46 provide the appropriate sequence of signal change timing indicators to manage the flow of data between N-Bank SDRAM 55 and the external din and dout busses.
Control/status router 48 modifies the functionality of SDRAM controller 38 based on control/status programming values. Initialization sequencer 49 restrains refresh module 51 , directs master state machine 42 to produce an initialization sequence to N-Bank SDRAM 55 , and reports to control/status router 48 when initialization is complete. Address generator 50 receives input from the external addr bus, control/status router 48 , and state machines 42 and 44 to send the appropriate address to N-Bank SDRAM 55 . Data buffer 54 temporarily stores data that is being transferred between N-Bank SDRAM 55 and the external din and dout busses.
FIG. 4 is a flow chart of a method 56 of processing requests for memory access in accordance with an embodiment of the present invention. Method 56 begins when the request for memory access is received by the arbiter in an operation 58 . The arbiter then determines whether there is a read in progress (RIP), a write in progress (WIP), or if the data bus is idle. After the arbiter determines the current state of the data bus, it then directs method 56 to the corresponding handler, either the RIP handler, the WIP handler, or the idle handler. The methods of each handler, all of which are optimized for maximum efficiency (the least amount of idle time) are described below.
FIG. 5 is a flow chart of a method 60 of processing a request for memory access when there is a read in progress on the data bus. Method 60 begins with an operation 62 , where the arbiter waits for Time ( 1 ), six phases before the end of the read in progress, to look for a read other bank to process during this first window of opportunity where the SDRAM can overlap transactions for maximum efficiency. At Time ( 1 ), an operation 64 determines whether there exists an other bank read request that has the highest priority of all the requests posted. If so, an operation grants memory access to the other bank read requestor to start a new address in an operation 66 , and then ends method 60 .
The read other bank request is granted first because it can be accomplished with no idle cycles between transactions when there is a read in progress. If there is no other bank read request or there is but it does not have the highest priority of the requests posted, then the arbiter waits until it is Time ( 2 ), three data phases before the end of the read in progress, to look for a read or other bank write, an operation 68 . If it is Time ( 2 ), an operation 70 determines whether there exists an other bank read request that is the highest priority request posted. If so, then an operation 72 grants memory access to the other bank read requester to start a new address, and then ends method 60 .
If not, an operation 74 issues a precharge to the command state machine to ensure that the SDRAM maintains its charge. The precharge also terminates the cycle, thereby eliminating an inefficient explicit termination cycle to the SDRAM. Method 60 then proceeds to an operation 76 , which determines whether there exists an other bank write that is the highest priority request posted. If so, then an operation 78 grants memory access to the other bank write requester, and ends method 60 . If not, method 60 then ends, and the process continues by returning to method 56 in FIG. 4 .
FIG. 6 is a flow chart of a method 80 of processing a request for memory access when there is a write in progress on the data bus. Method 80 begins with an operation 82 waiting for Time ( 1 ), four data phases before the end of the write in progress. At Time ( 1 ), an operation 84 determines whether an other bank read exists and is the highest priority request posted. If an other bank read is present and is request is the highest priority request posted, then memory access will be granted in an operation 86 , ending method 80 .
If a other bank read request is not the highest priority request posted, then an operation 88 waits until it is Time ( 2 ), three data phases before the end of the write in progress. Then, an operation 90 determines whether a write other bank is the highest priority request posted. If so, then memory access is granted to the write other bank requester in an operation 92 , ending method 80 . If not, an operation 94 waits until Time ( 3 ), one data phase before the end of the write in progress before issuing a precharge to the command state machine in an operation 96 . Method 80 then ends, and the process continues by returning to method 56 in FIG. 4 .
FIG. 7 is a flow chart of a method 98 of processing a request for memory access when the data bus is idle. Method 98 begins at an operation 100 which determines whether a request is posted. If a request is posted, then memory access is granted to the highest priority requestor in an operation 102 . Method 98 then ends, and the process continues by returning to method 56 in FIG. 4 .
FIG. 8 is a state diagram of BankA state machine 42 of FIG. 3 . The BankA state machine is reset into the precharge idle state (PRECH_IDLE) 104 , after which the state machine is initiated through control of the initiation sequencer with a mode register command (MRS_CMD) 106 , a precharge all command (PALL_CMD_tRP) 110 , and a series of auto refresh commands (ARES_CMD_tRC) 108 , which apply to all the banks. After returning to the precharge idle state 104 , an activate command (ACTV_CMD_tRCD) 112 is given to proceed to a write TBStartW 114 or a read TBStartR 116 , waiting the proper time between activate and read/write.
From TBStartW 114 , BankA state machine 42 enters a pre-write (PRE_WRITE) state 118 before proceeding to a write command (WRITE_CMD_DATA) state 120 . From TBStartR 116 , BankA state machine 42 proceeds to a read command (READ_CMD_CASLAT_DATA) state 122 . From the write command state 120 and read command 122 state, if the state machine receives an other bank termination write (OBTermW) 124 or an other bank termination read (OBTermR) 126 that changes the state to an other bank termination waiting for precharge (OBTERM_WPCH) 128 state. If an optimized situation does not exist from write command 120 and read command 122 , then a termination write with precharge (TermWP) 130 or a termination read with precharge (TermRP) 132 is executed. BankA state machine 42 then enters the precharge command (PCHB_CMD_tRP) state 134 before returning to precharge idle state 104 .
FIG. 9 is a state diagram of BankB-N state machines 44 of FIG. 3 . BankB-N state machines 44 are identical to BankA state machine 42 , except it does not include mode register command 106 , auto refresh command 108 , or precharge all command 110 .
FIG. 10 is a state diagram of data control state machines 46 of FIG. 3 after receiving a write command. Data control state machines 46 keep track of the data phase to find out when the window of opportunity is for overlapping transactions. When there is a grant (gnt[n]), and the pre-write state of the BankA or BankB on state machine has been entered, data control state machines 46 exit idle state 136 and enable a write direction first in first out unit (EnFIFO[n]) 138 . When a data terminal count occurs (DataTermCnt), the state returns to idle state 136 . Therefore, the most efficient write would have at least 1 idle cycle in between write commands.
FIG. 11 is a state diagram of data control state machines 46 of FIG. 3 after receiving a read command. Starting from idle state 140 , a start read (StartRead) command and grant are given, moving data control state machines 46 to enable a read direction the first in first out 142 until it receives a data terminal count. If there is a data terminal count and no grant, data control state machines 46 return to idle state 140 . If however, there is a grant, then the transition is made to enable another read direction first in first out unit (EnFIFO[others]) 144 on the very next clock. The second read is therefore accomplished with zero idle cycles between the second read and the first read.
FIG. 12 is a timing diagram of the state machines during consecutive read commands with next transfer termination. The diagram shows the commands read BankA (RDa), precharge BankB (PCHb), and activate BankB (ACTb) followed by read BankB (RDb), precharge BankA (PCHa), and activate BankA (ACTa), etc. This is the most optimized transaction because the opposite bank is perfectly utilized following the flow diagram shown in FIG. 11 . The timing diagram shows that the original bank and the opposite bank alternate three times in a row for the read command, and that the idle penalty is zero because there is no break in data bus usage (D[31:0]).
FIG. 13 is a timing diagram of the state machines during consecutive write commands with next transfer termination. The diagram shows the commands write BankA (WRa), precharge BankB (PCHb), and activate BankB (ACTb) followed by write BankB (WRb), precharge BankA (PCHa), and activate BankA (ACTa), etc. The opposite bank is utilized following the flow diagram shown in FIG. 10 . The timing diagram shows that the original bank and the opposite bank alternate three times in a row for the write command, and that the idle penalty is one for each transaction boundary.
FIG. 14 is a timing diagram of the state machines during a read, a write and then another read command with next transfer termination. The diagram shows the commands read BankA (RDa), precharge BankB (PCHb), and activate BankB (ACTb) followed by write BankB (WRb), precharge BankA (PCHa), and activate BankA (ACTa), etc. Again, there are opposite bank transactions, and there is one idle during the read, write opposite bank, and two idles during the read opposite bank (indicated by the second RDa).
FIG. 15 is a timing diagram of the state machines during three reads with precharge termination. The most important thing that the SDRAM does during variable length transactions is to terminate the existing transaction on time so that there is no overflow of data. As shown in FIG. 15, the window of opportunity for overlapping has passed making it impossible to terminate the existing transaction during the time that the next transaction is occurring. Therefore, a precharge termination is executed.
FIGS. 16-18 are timing diagrams of the state machines during various other operations with precharge termination. Again, in these cases, the window of opportunity to overlap transactions has lapsed resulting in several idle cycles. Therefore, a precharge termination is used as the last option to terminate the transaction on time.
FIGS. 19-20 are timing diagrams for processor read and processor write transactions. These transactions are only one data phase long. To overlap transactions, a certain length of transaction is required. For example, in the processor read transaction represented by the timing diagram in FIG. 19, a length of greater than six clocks is required, otherwise there is not enough time to overlap transactions. Therefore, no overlap occurs when processor read or write transactions are serviced.
In summary, the present invention provides for efficient use of the memory banks of a SDRAM for multiple variable length memory requests. In particular, the present invention maximizes use and reduces idle of the SDRAM memory banks by identifying a window of opportunity at which it is possible to overlap a second transaction with the current transaction, and processing the second transaction before the current transaction terminates. For example, if the SDRAM is currently processing a read or write from the memory banks, and receives a new memory request, the SDRAM controller will determine a time at which there is a window of opportunity. If at such a time, the proper request is posted, then the SDRAM controller will grant memory access to the request to the opposite bank.
The invention has been described herein in terms of several preferred embodiments. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. Furthermore, certain terminology has been used for the purposes of descriptive clarity, and not to limit the present invention. The embodiments and preferred features described above should be considered exemplary, with the invention being defined by the appended claims. | Disclosed is a SDRAM system including a SDRAM having multiple banks of memory, a plurality of bank state machines associated the multiple banks of memory of the SDRAM, and a data control state machine. The data state machine is responsive to a memory request for a variable length data transfer with the SDRAM and as well as the bank state machines. The data control state machine determines the current state of a first bank of memory of the SDRAM. The current state may be either a read in progress, a write in progress, or idle. The data control state machine then handles the memory request with a different bank of memory RAM depending upon the current state of the first bank of memory. | 6 |
BACKGROUND OF THE INVENTION
[0001] The invention relates generally to piping systems and in particular to a fitting for use with a tubing containment system. Currently, flexible piping, such as corrugated stainless steel tubing, is used in a number of applications requiring primary and secondary containment. Various plumbing as well as local and federal mechanical codes and specifications require that certain types of installations of flexible piping be protected by a secondary containment system. Tubing containment systems exist in the art to contain fluids if the tubing fluids. One existing tubing containment system is disclosed in U.S. Pat. No. 7,004,510, the entire contents of which are incorporated herein by reference. A threaded fitting for use with a tubing containment system is disclosed in U.S. patent application Ser. No. 12/207,626, the entire contents of which are incorporated herein by reference.
SUMMARY
[0002] Embodiments of the invention include a fitting for use with metal tubing in a jacket, the fitting comprising: an adapter, the adapter having a tubular member defining a longitudinal passage having a longitudinal axis for fluid flow; a body for receiving the tubing, the body positioned opposite the adapter and aligned with the longitudinal axis; a sealing member positioned between the adapter and the body; a retainer positioned external to the sealing member, the retainer receiving the adapter and receiving the body; a first flange located near the adapter and a second flange located near the body; and a fastener for drawing the first flange and second flange towards each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a cross-sectional view of an exemplary flanged fitting for use in a tubing containment system attached to tubing.
[0004] FIG. 2 is a cross-sectional view of the adapter of FIG. 1 .
[0005] FIG. 3 is a cross-sectional view of the body of FIG. 1 .
[0006] FIG. 4 is an enlarged, cross-sectional view of the ferrule of FIG. 1 .
[0007] FIG. 5 is a cross-sectional view of a fitting in an alternate embodiment.
[0008] FIG. 6 is an enlarged, cross-sectional view of a portion of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] FIG. 1 is a cross-sectional view of an exemplary flanged fitting coupled to a tubing containment system. The fitting includes an adapter 100 and a body 200 . Adapter 100 includes a longitudinal through passage 106 to allow fluid (gas, liquid, etc.) to flow. As described in U.S. Pat. Nos. 5,799,989, 6,079,749 and 6,428,052, adapter 100 interacts with a sealing member 300 to compress corrugated tubing between the adapter 100 and sealing member 300 to form a fluid tight seal. Sealing member 300 may be a formed by split ring washers, a collet or other member. Retainer 400 is used to keep the sealing member 300 in place and guide the body into position during use. A ferrule 500 engages the jacket 702 of the corrugated tubing 700 to mechanically secure the jacket 702 to body 200 . Ferrule 500 also creates fluid tight seal against body 200 as described in further detail herein.
[0010] FIG. 2 is a cross-sectional view of the adapter 100 of FIG. 1 . Adapter 100 includes a tubular member 102 defining through passage 106 along longitudinal axis 104 . A shoulder 108 extends away from tubular member 102 , and is generally perpendicular to longitudinal axis 104 . Flange 600 contacts shoulder 108 when the fitting is assembled as described herein. A guiding surface 110 tapers from the shoulder 108 , and has an oblique angle relative to the longitudinal axis 104 of the fitting. In an exemplary embodiment, the angle of the guiding surface 110 matches the angle of an inlet surface 402 on retainer 400 . Adapter 100 includes an o-ring groove 112 for receiving an o-ring that seals against the interior of retainer 400 . Adapter 100 includes an adapter sealing surface 114 that contacts the exposed corrugated tubing 700 and compresses the metal tubing 700 between the adapter sealing surface 114 and a sealing surface 302 on sealing member 300 . In an exemplary embodiment, the angle of the adapter sealing surface 114 matches the angle of the sealing surface on sealing member 300 .
[0011] FIG. 3 is a cross-sectional view of the body 200 of FIG. 1 . Body 200 includes an o-ring groove 204 formed on an exterior surface of the body at a first body end proximate the adapter 100 . An o-ring may be positioned in the o-ring groove 204 to provide an enhanced seal between the body 200 and the retainer 400 . Body 200 also includes features that provide for venting of fluid in the event of a fluid. Body 200 includes a vent opening 206 that extends through an exterior wall of body 200 . Vent opening 206 provides for egress of fluid leaking from tubing 700 ( FIG. 1 ). Sensors (not shown) may be placed in fluid communication with vent opening 206 for monitoring of leaking fluid.
[0012] A ferrule 500 is positioned on a rear end of the body 200 and engages the jacket 702 of tubing 700 ( FIG. 1 ). The ferrule 500 is received in a frusto-conical annular recess 208 on the rear of the body 200 where tubing 700 enters the fitting. The recess 208 has a recess surface having an angle “a” relative to a longitudinal axis of the fitting, 104 . In an exemplary embodiment, angle “a” equals 30 degrees.
[0013] FIG. 4 is an enlarged, cross-sectional view of the ferrule 500 of FIG. 1 . Ferrule 500 has a dual tapered surface 502 having a first section 504 and a second section 506 . The first section 504 has a steep angle (e.g., 45 degrees) to define a sharp edge 510 . This edge 510 is driven into the tubing jacket 702 when the fitting is assembled as described in further detail herein. The second section 506 has a more shallow angle “b” (e.g., 20 degrees). By making angle “b” less than angle “a” (on the recess 208 ) the edge 510 of ferrule 500 is driven towards the centerline of the body, into the jacket 702 . Edge 510 engages jacket 702 and provides a mechanical attachment between the body 200 and the jacket 702 . This provides a fluid-tight, mechanical attachment to the jacket 702 to control axial extension of the hose assembly under pressure. Also, the compression of ferrule 500 into the frusto-conical annular recess 208 and also provides a fluid-tight, metal-to-metal seal. Jacket 702 may be similar to that described in U.S. patent application Ser. No. 12/207,626.
[0014] In assembling the fitting to the tubing 700 , the tubing 700 is fed through flange 650 , ferrule 500 , and body 200 . The distal end of tubing 700 has the jacket 702 removed to expose at least one valley of the corrugated tubing 700 . Corrugated tubing 700 has an exterior surface of undulating peaks and valleys. Sealing member(s) 300 is placed in an exposed valley of corrugated tubing 700 . The tubing 700 is pulled back through the body 200 until the sealing member 300 contacts a shoulder 220 .
[0015] Retainer 400 is slid over the sealing member 300 . Adapter 100 is inserted into the retainer 400 , guided by guiding surface 110 coacting with inlet surface 402 . Flange 600 is positioned around tubular member 102 . Fasteners (e.g., bolts) 800 pass though openings 602 in flange 600 and engage threads 652 in flange 650 . In exemplary embodiments, four bolts are used.
[0016] As the bolts 800 are tightened, adapter sealing surface 114 contacts the exposed corrugated tubing 700 and compresses the metal tubing 700 between the adapter sealing surface 114 and a sealing surface 302 on sealing member 300 . As flange 600 and flange 650 are drawn towards each other, the compression of the metal tubing 700 between the adapter sealing surface 114 and the sealing surface 302 folds the metal tubing 700 to form two layers of metal between adapter sealing surface 114 and sealing surface 302 . This defines a metal-to-metal seal between the adapter 100 and tubing 700 .
[0017] Further, as the bolts 800 are tightened, the ferrule 500 is driven into frusto-conical annular recess 208 in body 200 . As the angle “a” of the recess 208 is greater than the angle “b” of second section 506 of tapered surface 502 , the ferrule 500 is driven into the jacket 702 . The edge 510 of ferrule 500 engages the jacket 702 to provide a secure fluid tight, mechanical connection. The compression of the ferrule 500 into recess 208 forms a fluid-tight seal between ferrule 500 and body 200 .
[0018] FIG. 5 is a cross-sectional view of a fitting 900 in an alternate embodiment. Many of the elements of fitting 900 are similar to those of fitting 100 , and bear the same reference numeral. Fitting 900 varies in that the adapter sealing surface 902 is different than adapter sealing surface 114 . FIG. 6 is an enlarged view showing the adapter sealing surface 902 . Adapter sealing surface 902 has the same angle relative to the longitudinal axis 104 as sealing surface 302 .
[0019] As shown in FIG. 6 , the adapter sealing surface includes a cutaway 904 rendering the surface area of the adapter sealing surface 902 less than that of sealing surface 302 . Cutaway 904 includes a first wall 906 substantially parallel to longitudinal axis 104 . As second wall 908 is substantially perpendicular to longitudinal axis 104 . In use, bolts 800 are tightened driving the adapter 100 into body 200 . This compresses metal tubing 700 between the adapter sealing surface 902 and sealing surface 302 as shown in FIG. 6 . As a peak of the metal tubing is compressed, the edge between sealing surface 902 and first wall 906 applies force to the tubing 700 to form an annular crimp 710 in the tubing 700 . This crimp serves as a line seal and accommodates imperfections in the tubing 700 due to weld seams, mechanical tolerances, etc.
[0020] The tubing containment system may be used in a number of applications including direct underground burial, above ground outdoor use, indoor use at elevated pressure for safety and other secondary containment and sensing systems for petrochemical lines.
[0021] 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 fitting for use with metal tubing in a jacket, the fitting including: an adapter, the adapter having a tubular member defining a longitudinal passage having a longitudinal axis for fluid flow; a body for receiving the tubing, the body positioned opposite the adapter and aligned with the longitudinal axis; a sealing member positioned between the adapter and the body; a retainer positioned external to the sealing member, the retainer receiving the adapter and receiving the body; a first flange located near the adapter and a second flange located near the body; and a fastener for drawing the first flange and second flange towards each other. | 5 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
This invention relates to the field of halogen element presence sensing and concentration measurement using solid state electrically responsive sensing elements.
An increased current awareness of the dangers attending both prolonged and intense exposure to chemicals in the environment has increased the need for sensitive and easily used detection apparatus. This awareness coincides with the increased popularity of chlorine and other halogen inclusive compounds as cleaning agents, sterilizing agents, chemical reactants, chemical weapons--involving biological and vertabraed object defense, and other industrial reactants. These chlorine and halogen containing materials have been recognized as significant threats to human welfare and, therefore, are deserving of careful precaution in exposure avoidance. Notwithstanding the awareness of potential harm from exposure to these compounds and their constituents, a satisfactory arrangement for measuring worker exposure and determining concentrations of these agents in an atmosphere has been unduly limited by the complexity and cumbersome nature of the heretofore used halogen responsive measurement apparatus. Many currently available chlorine detectors, for example, use the phenomenon of gas adsorption followed by dissolution in an electrolyte which contains bromine ions. A subsequent chemical oxidation reaction with these bromine ions yields an electrical current which has a magnitude that is proportional to the reaction kinetics. A significant limitation of this detector concept, making it inconvenient to use, is the need for a liquid electrolyte in its operation. Periodic replenishment of this electrolyte is essential and, therefore, creates a significant logistics burden which attends use of such instrumentation. In addition to this use burden, it is not possible to make a precise determination of the concentration of chlorine gas in the atmosphere using this detector apparatus since its indication is of a yet or no nature. The integrated solid state detector element is particularly attractive as an improvement on this existing detector technology and is therefore employed in the present invention measuring apparatus.
SUMMARY OF THE INVENTION
The present invention provides for the detection of chlorine and other gaseous halogen compounds with a solid state detector cell. In the detector cell, the halogen reacts with two portions of the cell structure. In this double reaction, the heat generated electrical resistance change in a thin film element component of the detector cell is supplemented by the heat generation and other effects attending a second reaction. The second reaction occurs between the encountered halogen element and the substrate member which bears or supports the thin film element. The thermal effects of these two reactions is additionally supplemented by an ion exchange phenomenon between the resistance element and the substrate member that also contributes to the change of resistance in the thin film member. Additional aspects of the invention involve use of detector cell elements selected in accordance with a specific chemical and thermodynamic selection criteria and the use of plural detection cells, each of a different response character to the halogen element being detected, in an array capable of unique halogen element identifications. Another aspect of the invention involves the use of a precision electrical resistance measurement technique in the thin film sensing element and correlation of the resistance change with both an absolute and a relative reference criteria.
It is an object, therefore, of the present invention to provide a solid state halogen detection element which employs a dual reaction sensing mechanism.
It is another object of the invention to provide a detection cell in which a response to a sequence of exposure events is cumulative.
It is another object of the invention to provide a cumulative effect detection cell in which the results of an individual exposure event can be time segregated.
It is another object of the invention to provide a thermally operating detection cell in which a plurality of chemical and/or physical reaction phenomena contribute to a measurable electrical characteristic change.
It is another object of the invention to provide a detection cell wherein the contribution of two chemical and/or physical reactions to a sensed condition are coupled together using a plurality of coupling mechanisms.
It is another object of the invention to provide a detection cell in which thermal or heat energy coupling between detection cell sensing elements is supplemented by ionic transfer between sensing elements.
It is another object of the invention to provide a sensing cell which operates on the principal of the Gibbs free energy relationship in a chemical/physical reaction.
It is another object of the invention to provide a sensing cell which can be fabricated from a plurality of different metallic and metallic halide combination parts.
It is another object of the invention to provide a detection cell arrangement in which a plurality of detecting component cells, each of a different metal plus metal halide pairing composition, provide a multiple approach identification of the halogen element being detected.
Additional objects and features of the invention will be understood from the following description and the accompanying drawings.
These and other objects of the invention are achieved by an apparatus for detecting the presence of gaseous first halogen components in an unknown mixture of gases which includes the combination of a detection substrate member comprised of a second halogen chemical compound of a first metal; a thin film electrical resistance detector element received on said substrate member and comprised of a second metal in metallic form; an apparatus for moving a stream of said unknown gas mixture over said detection substrate and detector elements; an apparatus responsive to the combined detector element unknown gas exposure and the substrate member unknown gas exposure resistance changes in said detector element for indicating the presence of said first halogen components in said unknown mixture of gases.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the physical arrangement of a halogen detector apparatus.
FIG. 2 shows the structure of a thin film detection cell usable in the FIG. 1 detector apparatus.
FIG. 3 shows an operating sequence for a detection cell in accordance with the invention.
DETAILED DESCRIPTION
FIG. 1 in the drawings shows an overall perspective exploded view of a halogen detector apparatus made in accordance with the invention. The detector apparatus 100 in FIG. 1 is comprised of a closable housing member 102 which is arranged to receive a closure member 104 in a gas impervious fitted relationship. The housing 102 and enclosure member 104 in FIG. 1 may be fabricated of plastic, polymeric, or possibly ceramic materials or other materials known in the art. The housing 102 may be fabricated as either an integral one-piece structure or as five individually fitted together pieces. The closure member 104 is held in a gas-tight fitted relationship with the housing 102 by way of machine screws or other fastening arrangements which are not shown in FIG. 1.
Received in the housing 102 in FIG. 1 is a cavity receptacle 106 that is capable of containing a halogen element detection cell of a type shown in FIG. 2 in the drawings. The receptacle 106 is surrounded by thermal insulating material 110 which fills the space between the receptacle and the interior walls of the housing member 102.
Communicating between the receptacle 106 and the exterior of the housing member 102 are a pair of pressure sealable conduit paths 108 and 112 by which electrical conductors described below may communicate with the detection cell apparatus received in the receptacle 106. Communicating with end regions of the receptacle 106 are the closure member mounted inlet and outlet gas conduits 120 and 122 which convey a gas stream under measurement into and away from the receptacle 106. Representative overall dimensions for the housing member 102 are shown at 114, 116 and 118 in FIG. 1, and a thickness dimensions for the closure member 104 is indicated at 128 in FIG. 1.
As is described below herein, it is desirable to maintain control over the operating temperature of a detection cell received in the receptacle 106 during use of the FIG. 1 apparatus. The presence of a combined heating/refrigeration apparatus in the FIG. 1 detection apparatus is indicated at 124 with a heat energy communicating path indicated at 126 in FIG. 1. The combination of an electrical resistance element with a Peltier effect semiconductor junction device may be used to embody the heating/refrigeration apparatus shown at 124 at FIG. 1, or alternatively, a gaseous refrigeration machine or other heating and cooling arrangements known in the art may be employed.
FIG. 2 in the drawings shows a detection cell made in accordance with the invention which may be used in the FIG. 1 detector apparatus for sensing the presence of chlorine or other gaseous halogen molecules in a flowing stream of gases. The detection cell 200 in FIG. 2 is shown in exploded perspective and consists of a thin film electrical resistance element 204 which is mounted in a substrate member 202 and then received on a carrier member 206 for housing in the receptacle 106 of FIG. 1 or in some other containment apparatus. Typical dimensions for a detection cell of the FIG. 2 type are shown at 230, 232, 234 and 236 in FIG. 2, the first three of these dimensions representing the length, width, and thickness of the substrate member 202 and the latter dimension representing the thickness of the thin film electrical resistance element 204.
The response of the FIG. 2 detection cell to the incidence of halogen gase is measured by way of changes in the electrical resistance of the thin film resistance element 204; such resistance change is sensed by way of the four-lead or four-point electrical measurement circuit generally indicated at 211 in FIG. 2. The electrical measurement circuit 211 consists of a current source 224 which is applied to outward extremity portions of the thin film resistance element 204 and a voltage measuring apparatus 222 which is used to measure the voltage drop induced across a selected portion of the resistance element 204 by the current from the source 224.
Current from the source 224 is applied to convenient prepared extremity points on the thin film structure 204 such as the equipotential face indicated at 212 in FIG. 2 and a similar face on the opposite end of the thin film element 204. Current application is by way of the electrical leads 218 and 220 which attach to the equipotential faces by way of thermal compression bonding, welding, or other attachment arrangements known in the thin film art. The equipotential faces 212 may reside on the top surface of the thin film resistance element in lieu of being located on the ends, as is represented in FIG. 2.
Voltage drop across the major portion of the resistance element 204 is sampled by way of the voltage measuring apparatus 222 and its leads 214 and 216 which attach to suitably prepared pad areas 210 and 228 that are disposed inward from the equipotential faces 212 but nevertheless toward extremities of the resistance element 204. Separation of the current and voltage nodes in the four-lead electrical measurement circuit 211 is, of course, desirable in order that the voltage signal observed at 222 represents only the voltage occurring across the body of the thin film resistance element 204 and exclude voltage components originating in the attachments between leads 218 and 220 and the equipotential surfaces and the body of resistance element 204.
The flows of the unknown or gas being tested by the FIG. 2 detection cell are indicated at 226 and 227 inig. 2. These dual flows are provided in keeping with one aspect of the invention wherein chemical and/or physical reactions between the gas components being detected and elements of the FIG. 2 detection cell occur not only on the gas exposed surfaces of the electrical resistance element 204, but also on the surfaces of the substrate member 202. Provision for the flow 226 and the reaction of unknown gas with the underlying major surface of the substrate 202 is provided by the separation flow space indicated at 208 in FIG. 2 and by the illustrated greater width of the carrier member 206 with respect to the substrate member 202. Other arrangements of the thin film electrical resistance element, substrate member 202 and carrier member 206 which provide for unknown gas flow over the resistance element and substrate surfaces are, of course, possible within the purview of the invention.
According to one aspect of the present invention, halogen components in the flow of unknown gases indicated at 227 in FIG. 2 reacts physically and chemically with the exposed surfaces of the thin film electrical resistance element 204 to release heat energy; this heat energy in turn elevates the temperature of the resistance element 204 and thereby changes its electrical resistance and the voltage measured at 222. The physical portion of the gas to thin film electrical resistance element reaction may involve either one or both of the phenomena of adsorption and absorption. Parenthetically, it is notable that in thin film settings, the distinction between the phenomena of adsorption and absorption is recognized to become somewhat academic in nature. These two phenomena are therefore referred to with the generic name "sorption" herein.
In addition to this sorption phenomenon between unknown gas and thin film resistance element 204, the detection cell 200 also employs the phenomenon of sorption between halogen components of the unknown flow and the substrate member 202. This additional reaction is also a heat energy liberating phenomenon with the liberated heat energy being conveyed by way of the intimate relationship between the substrate 202 and the resistance element 204 into the resistance element 204 where additional quantums of electrical resistance change result.
In addition to this communication of heat energy between the substrate 202 and the thin film resistance element 204, and in accordance with another aspect of the invention, the reaction of halogen components with the metal of the thin film electrical resistance element 204 and the metal halide of the substrate member 202 promote an enhanced diffusion of the halide salt ions produced at the surfaces of the electrical resistance element 204 into the crystalline structure of the metal halide substrate member 202. Conversely, the chemical halogen reaction produced in the crystalline metal halide substrate member 202 will experience enhanced diffusion into the thin metallic film of the electrical resistance element 204. This latter diffusion of substrate generated ions into the electrical resistance element 204 contributes yet another component to the electrical resistance change measured by the voltage at 222--a change responding to the incidence of halogen ions into the detection cell 200. In this later diffusion process, the change of the metallic thin film element's electrical resistance will be proportional to the concentration of the diffused, ionically-bonded impurities which act as electron scattering centers in the electrical resistance element 204. This change of electrical resistance will, in turn, be proportional to the concentration of the halogen gas that is initially sorbed.
These sorption reactions are supplemented by conventional chemical reactions which occur at the surfaces of the electrical resistance element 204 and the substrate member 202, the latter reaction being sensed by way of the thermal coupling between substrate and the thin film resistance element.
In order to achieve these several reactions between halogen components in the unknown gas stream and the thin film resistance element and the substrate member, a selection of materials used in fabricating the thin film resistance element and in the substrate member is necessary. One possible selection of materials for the FIG. 2 detection cell consists of the combination of a thin film resistance element 204 that is composed of metallic silver and a substrate member 202 which is composed of crystalline cesium bromide. If the silver-cesium bromide arrangement of the FIG. 2 detector is exposed to chlorine gas in a contaminated atmosphere, the chlorine gas will be sorbed on the metallic thin film and the following chemical and thermodynamic reactions will occur.
In the thin film element, the reaction:
Cl.sub.2 +2Ag→2AgCl+Q (1)
while in the metal halide substrate member 022, the reaction:
AgCl+CsBr→AgBr+CsCl+Q (2)
are to be expected.
The reactions of these two equations proceed in the indicated left to right direction and liberate heat energy in accordance with the Gibbs free energy phenomenon which is known in the art and which is explained, for example, in the published work entitled "Physical Chemistry", which is written by Clyde R. Metz and published by the McGraw-Hill Book Company, New York, 1976.
Table I shown below lists 21 possible metal and metal halide pair combinations, including the above silver and cesium bromide combination which might be employed in fabricating the FIG. 2 detection cell 200. The combinations of Table 1 are formulated according to the conditions implicit in the general reaction reaction:
nM.sub.1 Cl.sub.m +mM.sub.2 Γ.sub.n →mM.sub.2 Cl.sub.n +nM.sub.1 Γ.sub.m +Q (3)
where
M 1 is the thin, conducting metallic surface film material;
M 2 is the metal selected for the metal halide substrate member (M 1 ≠M 2 );
Γ is the halogen selected for the metal halide substrate member;
m and n are stoichiometric coefficients; and
Q is the heat energy liberated as a result of the reaction.
The Table I set of combinations was formulated according to the conditions implicit in equation 3; that is, a reaction between the thin film of the resistance element 204 and the incident halogen gas must be possible. If the theoretical change in isobaric and isothermic potentials, that is, the change in the Gibbs free energy level for each thin metallic film resistance element in Table I is identified as shown in the second column of Table I, the values of ΔG, that is the change of the Gibbs free energy, may be interpreted as follows:
A negative value of ΔG indicates the detection of chlorine is possible.
A positive value of ΔG indicates the impossibility of detecting chlorine gas.
TABLE I______________________________________Metal/Metal Halide Change of the Isobar-IsothermCombination Potential (ΔG) [kcal/mole]______________________________________Ag/CsBr -2.8Ag/KBr -3.3Ag/KI -9.6Ag/LiF +29.8Al/CsI +22.0Al/KBr +13.5Al/KI +16.0Bi/CsI -21.1Bi/KI -28.0Cu/CsBr -4.3Cu/KI -12.0Cu/LiI -27.0Cu/NaBr -10.0Cu/NaI -19.4In/CsBr +2.0In/Kl +5.0Mn/KBr +2.9Mn/KL +6.0Pb/CsI -1.8Pb/KI -7.0Tl/KBr -6.4______________________________________
In the Table I listing therefore, 13 of the identified metal and metal halide pairings, that is, the pairings having a negative number in the right-hand column of Table I, are potentially useful in the FIG. 2 detection cell apparatus. It is, of course, possible that some of the halide substrate compounds recited in the the left-hand column in Table I are impractical for use in the FIG. 2 apparatus according to the present state of the metal halide art. These compounds are nevertheless possessed of the desired energy relationship characteristics with respect to at least the halogen, chlorine, for use in the FIG. 2 apparatus and are, therefore, recited inTable I. Physical strength properties or other characteristics of some Table I listed compounds may also require modification of the support structure or other of the arrangements shown in the FIG. 2 apparatus.
It is notable that a detection cell made in accordance with the presently described concepts has the characteristics of cumulative non-recovering indication of reactant gas exposure. As is described in connection with the blocks 300 and 302 in FIG. 3 below, this cumulative exposure response is useful in some applications of the invention such as dosimeter devices, but also necessitates the consideration of exposure time interval and the negation or nulling out of previous exposure history in the case of a concentration measuring instrument made according to the invention.
The metal halide composition of the substrate member 202 provides an affinity for halogen gas components in the unknown gas flows 226 and 227 across the FIG. 2 detection cell surfaces. By considered selection of the thin film metal and metal halide pairings from Table I moreover, the degree of this affinity for a particular halogen can be emphasized in a particular use of the invention. In addition to such a "first level" enhancement of selectivity in a FIG. 2 detection cell to a particular halogen gas, it is also possible to increase the selectivity of an apparatus using the FIG. 2 detection cell, and thereby reduce or eliminate the possibility of spurious response to some component other than the intended halogen gas, by using a plurality of the FIG. 2 detection cells as component cells in a detector array.
Since each of the metal and metal halide pairings in Table I has a unique Gibbs free energy or ΔG value in the right-hand column of Table I, an array of multiple detection cells, each of a different Table I pairing and mounted in a common holder of the FIG. 1 type, will generate a plurality of electrical resistance responses that is unique in accordance with the type of gas in the unknown stream. According to this concept, if several discrete detector elements are fabricated from the universe of possible combinations shown in Table I and mounted in a common chamber of the type shown in FIG. 1, the incidence of a low concentration of chlorine gas, for example, will produce a distinct electrical resistance change in each detector element, and the array of these resistance change values is unique to chlorine gas since any other gas will produce a different ratio of resistance changes inthe array than will a change of chlorine concentration or the introduction of elements in addition to chlorine to the unknown stream. By way of this array of multiple resistance change signals, it is also possible to select response patterns that are identifiable for each of the different halogen gases of interest in a detection environment.
Electrical signal multplexing as is commonly practiced with microprocessors and other computer devices, may be employed for the collection of multiple signals from a detector array. Processing of the electrical resistance change signals for each detection cell in the array is based on the absolute resistance change displayed by each cell and also on the ratio and difference comparisons of the change in individual cell resistances.
FIG. 3 in the drawings illustrates the method of the present invention halogen detection. In the FIG. 3 steps, the reaction of an unknown gas with the thin film electrical resistance element 104 is indicated in the block 300 while the reaction of the unkniown gas halogen component with the selective metal halide substrate is indicatd in the block 302 and the communication of liberated energy and the ionic communication between substrate and thin film resistance element is indicated in the block 304. Measurement of the electrical resistance change in the thin film element, as is performed by the electrical measurement circuit 211 in FIG. 2, is indicated in the block 306 of FIG. 3 and the correlation of resistance change to halogen gas concentration is indicated in the block 308.
Since the physical/chemical reaction between halogen gas and halide substrate and metallic thin film elements is unidirectional or irreversible in nature--insofar as the present instrumentation environment is concerned, the electrical resistance changes experienced in the thin film element 204 include a cumulative or past history related component which is both desirable and also in some uses of the apparatus, necessitating of additional apparatus complexity in order to be accommodated.
In a dosimeter application of the FIG. 2 detection cells, this cumulative effect has the desirable ability of measuring the integrated or "area under the curve" total exposure of the dosimeter's test subject when read out following an extended period of exposure or exposure and non-exposure intervals. The cumulative exposure nature of the FIG. 2 cell characteristics is therefore a desirable characteristic in dosimeter uses of the invention.
In an instrument which measures concentration of a component gas in an unknown flow, the cumulative nature of the detector element resistance change must be taken into consideration and the "non-zero" starting point for a new exposure recognized. Electrical bridge circuitry and other known differential measurement techniques in which comparison with a non-zero reference or initial value of an unknown, in fact, compensates for the non-zero value of the initially measured signal. These techniques can also be used to accommodate this cumulative effect non-zero starting point in a sensor.
The duration of the exposure time between halogen gas and sensing elements is also a consideration in an integrating or cumulative effect sensor, since it allows segregation of a resistance change arising from long exposure to a low concentration and the same resistance change arising from a short duration exposure to a high concentration of the same gas. Consideration of exposure time, as indicated symbolically at 310 and 312 in the FIG. 3 method sequence, can be embodied in the FIG. 2 apparatus in the form of time-gated control of the flows 226 and 227.
While the apparatus and method herein described constitute a preferred embodiment of the invention, it is to be understood that the invention is not limited to this precise form of apparatus or method, and that changes may be made therein without departing from the scope of the invention, which is defined in the appended claims. | A solid state thin film detection and measurement apparatus for halogen gas components such as chlorine in a gas mixture is described. The detection cell employs plural response modes to the halogen gas including response to the thermal effect of a halogen and thin film reaction and response to the thermal and ion diffusion effects of the halogen reaction with a halide supporting substrate member. These plural responses are manifested by an electrical resistance change in the thin film element and this change is sensed with a four-lead measurement arrangement. The use of plural measurement cells each of a different composition and computerized multiplexing of thin film resistance signals is included as are identification of possible thin film and substrate compositions. | 6 |
FIELD
The invention relates to a damping unit for an elevator. Elevators contain cars that can be moved in an elevator shaft by means of a drive unit, via a suspension means in the form of a suspension cable or suspension belt, for example. Guide rails are installed in the elevator shaft, which define a linear guide for the elevator car. Persons or freight entering or exiting the stationary elevator car cause an undesired vertical oscillation of the car due to the elasticity of the suspension means. Such vertical oscillations occur in particular with elevators using suspension belts for the suspension means, which have gained in popularity in recent times. Because belts exhibit impractical vibratory characteristics in comparison with steel cables, the vertical oscillations have an increasingly negative effect on the comfort of the passengers and the on the operational reliability.
BACKGROUND
A device for preventing vertical oscillations of the elevator car during standstill phases has become known from EP 1 067 084 B1. The device has a brake caliper, which can be pressed against the guide rails via a compound lever mechanism. Brake shoes are disposed on the front ends of the brake caliper lever. This device causes a more or less rigid securing of the car to the guide rails as a result of friction. It has been shown, however, that in practice such securing devices place high demands on control and regulating technology. In particular, it is difficult, or complicated, respectively, to operate the elevator in such a manner that it is possible to smoothly initiate movement of the car after it has been at a standstill.
Instead of securing devices, it is also possible to achieve a sufficiently pleasant feeling of comfort for the passengers during a standstill of the car if the vertical oscillations of the car are simply damped, or reduced, for which purpose significantly smaller forces are required. A damping unit for reduction of vertical oscillations of the car during standstill phases is demonstrated, by way of example, in EP 1 424 302 A1. The damping unit exhibits a lever arm, extending over approximately half of the depth of the car, on the free end of which a pivotally supported brake shoe is disposed. The damping unit is mechanically coupled to a door opening unit for the car; this damping unit, which can be activated by the drive unit for the door, requires complicated lever and gear mechanism mechanics, for which reason this solution is expensive and prone to malfunction. The device also cannot be retrofitted to already existing, older elevator facilities. Another disadvantage is that the damping characteristics of the car do not satisfy higher demands regarding operational comfort and reliability.
An assembly for the reduction of vertical oscillations of an elevator car during a standstill is known from WO 2011/021064 A1, with which brake shoe retainers centrally attached in an articulated manner to a lever arm can be moved against the guide rails by means of a cylinder powered by an electric motor, wherein the lever arms are pivotally adjoined at their lower ends to a base plate attached to a component of the car frame. The electric motor cylinder, installed in a transverse manner, is connected in an articulated manner to the opposing upper ends of the lever arms. The lever arms, provided with brake shoes, must be pivoted back and forth by means of the electric motor cylinder in order to alternate between the active position and the resting position. Both lever arms have a two-piece design, wherein the respective lever arm components can each be pushed against one another via a spring-supported damping mechanism comprising a helical compression spring. Undesired vertical oscillations during a car standstill are difficult to eliminate with this assembly, this being possible only with a high expenditure in terms of the control technology. Aside from the complicated construction, the assembly is also expensive and heavy. There is also the disadvantage that the assembly requires a lot of space.
SUMMARY
For this reason, one object of the present invention is to eliminate the disadvantages of the known damping units, and in particular, to create a damping unit with which the vertical oscillations of the elevator car during a standstill can be reduced in an optimal manner. The damping unit should furthermore be suitable for installation in existing facilities. A retrofitting of the elevator facility should be possible in a simple manner, and with comparatively low costs.
These objectives shall be achieved according to the invention with a device having a damping unit, preferably equipped with two brake shoes, that contains brake shoe retainers, which are functionally connected to an actuator for moving the brake shoes. The brake shoes can move, when not in use during movement of the car, along a guide rail, without contact to said guide rail. After the actuator has been activated, which is connected to the brake shoe retainer in the manner of a gear mechanism, the brake shoes retained by the brake shoe retainers are pressed against the guide rails in an active position when the car is at a standstill. The damping unit further comprises a housing or some other supporting structure (e.g. in the form of a simple mounting plate) for the brake shoe retainer. Because the actuator is connected to the brake shoe retainers via a gear mechanism, an advantageous connection in the manner of a gear mechanism between the brake shoe retainers and the actuator is obtained. Because of the gear mechanism, the brake shoe retainers, and thus the associated brake shoes as well, can be activated together in an efficient manner. A single gear mechanism thus enables a precise simultaneous movement of the two brake shoe retainers.
The gear mechanism can be designed, for example, as a spur gear gear mechanism, and exhibit a central drive gearwheel adjoining a drive shaft for the motor, and connected thereto such that it cannot rotate in relation thereto. Furthermore, the gear mechanism can have two eccentric gearwheels, wherein one eccentric gearwheel is allocated to one brake shoe in each case. The resting position or the active position can be defined for the brake shoes according to the rotational position of the central eccentric gearwheel, which can be driven by the drive gearwheel.
The eccentric gearwheels can have bearing pins that are disposed eccentrically (i.e. each eccentric gearwheel has one bearing pin), which each engage in bearing seats in the brake shoes in order to move the brake shoe retainers. The bearing pins define the resting position or the active position, depending on the rotational position.
The brake shoes can each be supported via at least one spring element in a cushioned manner on the respective or associated brake shoe retainers, whereby it is possible to set an optimal pressure for the brake shoes against the guide rails in the active position in order to reduce the vertical oscillations of the car. With the normally vertical guide rails it is thus possible to apply a precise and exactly defined horizontal axial force, and as a result, a defined vertical damping force can be obtained. A further advantage of the cushioned support of the brake shoes on the brake shoe retainers is that a robust, durable damping unit is created. The wear to the brake shoes has no, or very little, negative effect on the operational reliability of the damping unit. The design described here, having brake shoes supported in a cushioned manner on the brake shoe retainers via spring elements, could also be advantageous for damping units of the conventional design, i.e. for damping units of the type specified in the introduction. In this case, the gear mechanism described above need not necessarily be used.
In particular, metal springs are suited for use as the spring element. In a preferred embodiment the spring element can be a helical compression spring. The damping unit can have one, two or even numerous helical compression springs for each brake shoe.
It may further be advantageous if the brake shoes are disposed on the brake shoe retainers such that they can be displaced to a limited extent. For the limitation of the displacement path, the brake shoe retainers can be equipped with corresponding stops.
The brake shoes can be attached to support elements, or rest against such elements. The support elements can be made of a metal substance, such as steel, for example. For a spring-cushioned support of the brake shoes, the spring elements can abut the support elements on one side. In this manner, the spring elements can abut the brake shoe retainers on one side and the support elements on the other side.
For an optimal adjustment of the damping force, it is advantageous if the actuator comprises, preferably, a motor that can be driven electrically. This motor can be designed, for example, as a stepper motor, with which the desired pressure force can be set with great precision for reducing the vertical oscillations of the car.
It may be particularly advantageous, furthermore, if the damping unit has a shared motor for moving both brake shoes, with which the brake shoe retainers can move simultaneously, but in opposite directions.
The damping unit can have a supporting structure, formed, for example, by a housing, on which the brake shoe retainer is disposed, and preferably is supported such that it can be displaced. In the latter case, the direction of displacement would be transverse to the direction of travel for the car.
The damping unit can have an eccentric assembly, by means of which the brake shoes can be moved back and forth. Because of the eccentric assembly it is possible to adjust the resting position and the active position of the brake shoe retainer in a particularly simple and efficient manner. In particular, the eccentric mechanics enables a precise and, at the same time, simple pressurization of braking surfaces with a pressure force having a high transmission of force for reducing the vertical oscillations of the elevator car during standstill phases, whereby small actuators (e.g. electric motors) can be used.
Furthermore, the damping unit can have a spring device attached to the supporting structure, which can be attached to the car, and which serves as the spring-cushioned support for the supporting structure, resulting in a series of advantages. Undesired lateral displacements of the car transverse to the direction of travel can be absorbed and reduced in a simple manner with the spring device. Furthermore, production and assembly related tolerances between the guide rails and the brake shoes do not have a negative affect thereon.
The spring device could, for example, contain one or more conical helical compression springs. It is particularly advantageous, however, if the spring device is designed as a flexible spring made of metal. The flexible spring can be designed such that it can only be displaced in a two-dimensional manner. Furthermore, flexible springs have the advantage that they can be connected to both the supporting structure as well as the car. Flexible springs can also be manufactured in a simple and cost-effective manner. Lastly, flexible springs can be optimally adjusted to the desired degree of freedom.
It is particularly advantageous that the spring device is formed by a box-like profile, having a basically C-shaped cross-section. With a C-profile of this type, the desired two-dimensionally spring-cushioned support of the supporting structure can be achieved in an advantageous manner. The C-shaped profile can be disposed, or positioned, respectively in the damping unit, such that the longitudinal direction of the C-profile runs parallel to the braking surface of the brake shoes. A further advantage of a spring device of this type is that the hollow space defined by the C can be used to receive a guide shoe, entirely or in part, by means of which it is possible to obtain a compact elevator car having comparatively low structural heights.
The spring device can have a fastening section on or adjoining the supporting structure, for securing the supporting structure and two opposing lateral walls, adjoining the fastening section, preferably at basically a right angle. Furthermore, end sections can adjoin the lateral walls, in each case running parallel to the fastening section, via which the damping unit can be attached to the car. The end sections can have fastening means for securing the spring unit to the car, e.g. in the form of holes for receiving screws.
The invention can further relate to an elevator having a car and having at least one damping unit of the type of damping unit described above. The spring unit is disposed between the supporting structure and the car, and forms, to a certain extent, a spring-cushioned interface to the car for the damping unit.
DESCRIPTION OF THE DRAWINGS
Further individual features and advantages of the invention can be derived from the following description of one embodiment example, and from the drawings. Shown are:
FIG. 1 is a simplified depiction of an elevator in a side view,
FIG. 2 is a depiction of a damping unit according to the invention, for the elevator,
FIG. 3 is a cross-section cut through the damping unit (line A-A in FIG. 2 ),
FIG. 4 shows a gear mechanism for the damping unit according to FIG. 2 ,
FIG. 5 is a perspective exploded depiction of the damping unit,
FIG. 6 is an enlarged depiction of an assembly, having a brake shoe retainer and a brake shoe for the damping unit according to FIG. 2 , and
FIG. 7 is a perspective exploded depiction of the assembly in FIG. 6 .
DETAILED DESCRIPTION
FIG. 1 shows an elevator having a car 2 that can be moved up and down for transporting people or freight. Suspension means 34 designed, by way of example, as belts or cables, serve as the suspension means for moving the car 2 . For the guidance of the car 2 , the elevator facility has two guide rails 3 extending in the vertical direction z. Each guide rail 3 has three guide surfaces thereby, extending in the direction of travel for the car. Guide shoes, designed in FIG. 1 , by way of example, as roller guide shoes 14 and 15 , are attached to the car 2 . It is possible to reduce undesired vertical oscillations of the car during a standstill by means of the damping unit, indicated with the numeral 1 . Vertical oscillations of this type occur when people enter or exit the car 2 . The car 2 begins to oscillate as a result of the change in the load. This phenomenon is strongly pronounced, in particular, in suspension belt elevators having high shaft heights. The letter z indicates the direction in which the guide rails extend, and the arrow z also indicates the direction of travel for the car 2 .
In order to reduce these vertical oscillations, the elevator facility has damping units 1 disposed on both sides of the car 2 . The two damping units 1 can be activated by a (not shown) control device. It is, however, frequently sufficient to equip the elevator car with only one damping unit, because the guide rails need only be subjected to comparatively small forces in order to obtain a sufficient damping behavior of the car. In this manner, it is also possible to save on costs. The control device transmits a control command to the damping units as soon as the car stops, for example, or when the car door opens. The activation is normally maintained until the doors are again closed, and thus it is no longer possible to substantially change the load thereto. During the activation, the control device can transmit further regulating commands for the damping units.
In the embodiment example according to FIG. 1 , the damping units 1 are attached, by way of example, to the top of the car 2 , wherein they are located separately from the upper guide shoes 14 . Depending on the configuration of the car and spatial requirements, the guide shoes and damping units can also be combined with, or disposed in relation to, one another, in another manner. In this manner, the at least one damping unit could also be attached to the bottom of the car. As can be derived, basically, from the following FIG. 2 , the damping unit 1 can be attached to a console, which encompasses the guide shoe 15 , either entirely or in part. In FIG. 2 , the aforementioned console is designed as the spring device, indicated by the numeral 6 , and to be described in detail below. The guide shoe 15 , designed as a sliding guide shoe, and indicated by a broken line, is visibly encompassed by the device 6 in a “C” shape.
A damping unit 1 is depicted in FIG. 2 in a lateral front view. The damping unit 1 contains two opposing brake shoes 7 , wherein each brake shoe faces one of the planar parallel guide surfaces of the (not shown here) guide rails. Each brake shoe 7 is retained by a brake shoe retainer indicated by the numeral 8 . The brake shoe retainers 8 are guided laterally on guide elements 16 , and can be moved toward the guide rails, or moved away therefrom. The respective directions of movement are indicated with arrows s. The individual guide elements 16 are attached to a housing 20 by means of screw fasteners 36 .
The brake shoes 7 are supported, together with support elements 9 , in a spring-cushioned manner on the brake shoe retainers 8 . The brake shoes 7 yield when brought into contact with the respective guide surfaces of the guide rails, and move back in relation to the brake shoe retainers 8 in the w-direction. Further details in this regard can be derived from FIGS. 6 and 7 .
A box-like profile, having a C-shaped cross-section, is disposed in the region of the top surface of the housing 20 , which shall be referred to in the following as the “attachment section” 21 ( FIG. 2 ). This C-profile forms a spring device 6 , by means of which the housing 20 is supported in a spring-cushioned manner, together with the brake shoes 7 and the brake shoe retainer 8 disposed thereon, on the car, indicated by the numeral 2 . The spring device 6 , formed from sheet metal by means of a folding process, has a fastening section 21 , lateral walls 22 adjoined thereto at a right angle, and end sections 23 adjoining the lateral walls at a right angle. The C-profile for the spring device 6 is preferably produced from a blank made of sheet steel. It is particularly preferred that spring steel is used thereby. The spring device 6 is thus clearly designed as a metal flexible spring. The spring deflection of the spring-cushioned support created by the spring device 6 is indicated by a double arrow v. The specific design of the spring device 6 results in a parallelogram configuration, which enables a basically parallel displacement of the housing 20 toward the bottom of the car 2 in the v-direction, or horizontally, transverse to the direction of travel z.
The end sections 23 of the spring device 6 lie flush on a part of the car 2 , and are connected in a fixed manner thereto by means of a screw connection 37 . The aforementioned car part can be formed, for example, by a car floor, a support frame for the car, or by another part allocated to the car.
Further details of the damping unit 1 can be discerned from the partial depiction according to FIG. 3 . Furthermore, the guide rail 3 is depicted here. In the resting position shown in FIG. 3 , the brake shoes 7 can travel along the guide rails 3 during movement of the car, without making contact therewith. During a standstill, the brake shoe retainers 8 are pushed, together with the brake shoes 7 disposed thereon, against the guide rails 3 . The pressing of the brake shoes 7 against the respective guide surfaces of the guide rails 3 results in a limited friction, and thus in a reduction of the vertical oscillations of the car caused by changes in the load thereto. The activation can be triggered thereby, by way of example, through the opening of the door, or, if necessary, already prior thereto (e.g. as soon as the car is at a standstill). In the present case, an electric motor, indicated by the numeral 4 , serves as the drive for moving the brake shoe retainer 8 . As a rule, however, other actuators could also be taken into consideration, such as a linear actuator. The gear mechanism-like connection comprises a gear mechanism 10 and an eccentric gear assembly for converting the rotational movement to the linear movement in the s-direction.
The gear mechanism 10 has a central drive gearwheel 11 , connected to the drive axle 17 ( FIG. 5 ) of the electric motor 4 , which drives the gearwheels, indicated by the numerals 12 and 12 ′. As can be derived from FIG. 3 , as well as the following FIG. 4 , the gear mechanism 10 is designed as a spur gear gear mechanism. As a matter of course, other types of gear mechanisms are also conceivable. The bearing pins 13 and 13 ′ are disposed eccentrically to the rotational axes R of the gearwheels 12 , 12 ′, for which reason the two gearwheels 12 , 12 ′ shall be referred to as “eccentric gearwheels” in the following. The respective eccentric gearwheels 12 , 12 ′ are non-rotatably connected to axle components 18 on which the bearing pins 13 are formed at the end surfaces.
Details regarding the arrangement and function of the gear mechanism 10 in the damping unit are shown in FIG. 4 . The respective eccentric gearwheels 12 , 12 ′ are permanently connected in a form-locking manner to the axle component 18 , which can rotate about the rotational axis R, via a shaft-hub connection. In the resting position shown here, the tappets 19 (e.g. fitted keys) face one another. The bearing pins 13 or 13 ′ are received eccentrically in a bearing hole in the brake shoe retainer, such that they can rotate, and function together with the respective bearing holes such that when the bearing pins 13 , 13 ′ rotate, the brake shoe retainers, and thus the brake shoes as well, can be moved back and forth horizontally. It is clearly visible in FIG. 4 that the geometric axis of the bearing pin 13 is not aligned with the rotational axis R of the eccentric gearwheel 12 , and is thus disposed eccentrically. In order to obtain the active position, the motor is activated. The bearing pins 13 , 13 ′ connected to the motor via the gear mechanism then rotate 180° in each case about the R-axes, whereby the brake shoes are pushed against the corresponding guide surfaces of the guide rails, and pressed against them.
The individual components of the damping unit can be seen in FIG. 5 . An assembly comprises, in each case, one brake shoe 7 and one brake shoe retainer 8 , which can move laterally, back and forth, on rail-like guide components 16 , transverse to the direction of travel, or to the longitudinal direction of the profile of the guide rails. A separate assembly can be seen at the bottom right region in FIG. 5 , the brake shoes and brake shoe retainer are indicated here with the numerals 7 ′ and 8 ′. It is thus clear from FIG. 5 that the supporting structure is substantially a three-part construction, and consists of a housing bottom part 26 , a housing upper part 25 , and a housing part 27 having a U-shaped cross-section when seen from above. The guide components 16 ′ are attached to the housing part 27 by means of bolts 36 . 2 and nuts 36 . 1 . The gear mechanism 10 can be pre-installed on a back wall 24 made of sheet metal, which is then installed in the rest of the housing during the final installation.
The spring device 6 , executed as a C-shaped flexible spring, has end sections 23 facing one another, which exhibit holes 30 for screw fasteners for attaching the spring device 6 to the (not shown here) car. The spring device 6 is attached and thus secured, in a region on the top surface 25 , to the damping unit housing by means of screws 33 .
FIGS. 6 and 7 show an assembly (or brake shoe unit, respectively) having a brake shoe retainer 8 and brake shoes 7 . The brake shoes 7 can be made from a metal material. The brake shoes 7 can also be made from a plastic material, or a mixture of materials. Advantageous braking surfaces for the intended reduction of the vertical oscillations of the car can be obtained, for example, when the known brake pads, referred to, at least in the automotive industry, as “semi-metallic,” “organic,” or “low-metallic” brake pads, are used for the brake shoes.
The brake shoes 7 lie on a comparably rigid support element 9 made of steel. The brake shoe 7 supported on the support element 9 is supported in a spring-cushioned manner via two helical compression springs 5 on the brake shoe retainer 9 . The arrow w indicates the direction of movement for the return movement of the brake shoe 7 when pressure is applied to the guide rails. The brake shoe 7 is disposed on the brake shoe retainer 8 such that it can be displaced to a limited extent, together with the associated support element, limited by means of bolts 31 and nuts 32 . Depending on the requirements, the inner, or front nuts 32 can be tightened to the extent that the brake shoe 7 is pre-tensioned. The outer, or rear nuts serve as counter-nuts. In order to ensure a linear movement of the brake shoe 7 to the greatest possible extent when pressed against the guide rail, a cylindrical guide pin 28 is disposed on the brake shoe retainer, and a guide recess 29 is disposed in the supporting element, complementary to the guide pin.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | An elevator damping unit for reducing vertical oscillations of an elevator car when at a standstill, has brake shoe retainers provided with brake shoes. The brake shoe retainers are connected to a common electric motor via a toothed gear mechanism. The toothed gear mechanism has a central driving gearwheel, which adjoins a drive shaft of the motor, and eccentric gearwheels, which are each assigned to one of the brake shoes and are in operative connection with the driving gearwheel. The brake shoes are supported resiliently on the respective brake shoe retainers in each case via two helical compression springs. | 1 |
The present invention relates to a rudder arrangement for ships, more particularly a rudder arrangement for ships having a main rudder member provided with a flap member pivotally mounted thereon at trailing edge.
DESCRIPTION OF THE PRIOR ART
The prior art is generally cognizant of the rudder arrangement for ships having the main rudder member with its flap member pivotally mounted thereon at the trailing edge. Examples of such rudder arrangement are known in U.S. Pat. No. 4,307,677, German Patent Laying-open publication No. 2,656,738 and No. 2,709,666 and Japanese Patent Publication No. 20400/1973.
In U.S. Pat. No. 4,307,677, German Patent Laying-open Publication No. 2,656,738 and Japanese Patent Publication No. 20400/1973, each of flap members is provided with a driving mechanism mounted inside thereof. German Patent Laying-open Publication No. 2,709,666 reveals a driving means with a link mechanism mounted on top of the flap member, which link mechanism is connected to actuating means such as an electric motor, located within a hull structure at the aft end of ship. However, no prior art is known which utilizes a train of gears located between a driving shaft of the main rudder member and a pivot pin of the flap member in a level above both members.
SUMMARY OF THE INVENTION
The present invention is summarized in that a rudder arrangement for ships having a main rudder member rotatably mounted on hull structure and a flap member pivotally mounted on said main rudder member at the trailing edge thereof, comprises a horizontal sector member mounted on the flap member in a level above the top end of the main rudder member and having teeth concentric with vertical pivot pins mounting said flap member on said main rudder member, and a stationary horizontal guide member of U-shaped cross-section located at the same level as said sector member and having an open end of an U-shaped sector member fixedly mounted on a support member depending from the hull structure with a rudder shaft embraced in the opening of the U-shape and provided at the closed end of the U-shape with teeth concentric with the rudder shaft in mesh with those of the sector member.
An object of the present invention is to construct a marine rudder with a flap member having a number of components located in a restricted space between the hull structure and top end of the rudder, which space is made as small as possible so as to simplify the whole structure and minimize the cost of construction and maintenance.
Another object of the present invention is to construct a marine rudder with a flap member operating smoothly without using any actuating means connected to a power source, such as electric motors or hydraulic systems, particularly for driving the flap member relatively to the main rudder member.
Still another object of the present invention is to construct a marine rudder with a flap member having a driving mechanism for the flap member assembled together easily by using a number of rather small-sized gears even when the size of the main rudder is substantially increased.
Still another object of the present invention is to construct a marine rudder with a flap member which is compact and free from intricate fittings precluding the inspection thereof.
Other objects, advantages and features of the invention will be apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view showing the rudder arrangement according to the present invention;
FIG. 2 is a plan view taken along a line II--II in FIG. 1;
FIG. 3 is a perspective view showing essential parts of the rudder in FIG. 1;
FIG. 4 is a plan view showing the operation of the rudder in FIG. 1;
FIG. 5 is a plan view showing a modification of the embodiment in FIG. 1; and
FIG. 6 is a plan view showing another modification of the embodiment in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a rudder 10 according to the present invention, comprising a main rudder member 1 rotatably mounted on hull structure 20 by means of a rudder shaft or stock 3, and a flap member 2 pivotally mounted on the main rudder member along the trailing edge thereof. The main rudder member 1 is suspended from the hull structure 20. The flap member 2 is mounted on the main rudder member 1 by means of a pair of pivot pins 11A, 11B, which are located adjacent to the top and the bottom end of the main rudder member 1. A center line of the pair of pivot pins 11A, 11B is placed parallel to that of the rudder shaft 3. As shown in FIG. 2, the main rudder member 1 and the flap member 2 are shaped such that cross-sections of both members 1 and 2 will form a complete aerofoil section when assembled together.
The top end of the flap 2 is placed in a level higher than the top end of the main rudder 1. A sector member 4 mounted at the left end of rudder 1 on the top end of the flap member 2, extends horizontally toward the rudder shaft 3 with its right end placed forwardly beyond the pivot pin 11A. As shown in FIG. 2, the sector member 4 is shaped semi-circular at its right end, which has a center of circle on a vertical center line axis YY of pivot pins 11A, 11B. More particularly, the sector member 4 has a semi-circular shape on its right side or forward side of vertical transverse plane TT passing the center line YY of the pivot pin 11A and is provided on this portion with teeth 7 of a spur wheel. The sector member 4 has a wedge-shaped configuration on the left side of the vertical transverse plane TT with its width decreased gradually. The sector member 4 is provided with a circular opening 12 immediately above the pivot pin 11A enabling the same to be passed therethrough for servicing.
A horizontal U-shaped guide member 5 embraces the rudder shaft 3 in the opening 13 of the U between its two leg portions 14A, 14B which extend rightwardly or forwardly. Further, the guide member 5 is fitted over a lower end of support member 6 depending from the hull structure 20 adjacent to the rudder shaft 3 with the support member 6 between the pair of leg portions 14A, 14B, thereby supporting the guide member 5 in a predetermined position. A suitable filler member 9 is inserted between the pair of leg portions 14A, 14B on the right side of the support member 6. The guide member 5 is provided on its left half portion with teeth 8 of a spur wheel concentric with the rudder shaft 3, with which teeth 8 and the teeth 7 of the sector member 4 will be brought into engagement.
As shown in FIG. 3, the guide member 5 is a stationary horizontal member mounted on the support member 6 at lower end thereof depending from the hull structure 20 and the rudder shaft 3 will be rotated in the opening 13 of the guide member 5.
As shown in FIGS. 2 and 4, the main rudder member 1 and the flap member 2 are assumed to have been initially in a fore and aft vertical plane XX passing through the center line 00 of the rudder stock 3; then pivot pins 11A, 11B will be placed in a vertical plane X 1 X 1 which is at an angle α with respect to the fore and aft vertical plane XX passing through the center line 00 of the rudder shaft 3, if the rudder shaft 3 is rotated by an angle of α when steering. Hence, the sector member 4 will be rotated onto the phantom line position (FIG. 4) from full line position by action of teeth 7 thereof engaged with teeth 8 of the guide member 5. Since the sector member 4 is fixedly mounted on the flap member 2, an angle between the flap member 2 and the main rudder member 1 which is swung around by an angle of α, will be equal to an angle β between the vertical plane X 1 X 1 in which the main rudder member 1 is placed and a vertical plane ZZ in which the sector member 4 is placed. The vertical plane ZZ, in which the flap member 2 is placed when the main rudder member 1 is swung by the angle of α, will form an angle of γ with respect to the vertical plane XX in which the main rudder member 1 and the flap member 2 had been placed initially before steering. Assuming that diameters of both spur wheels having teeth 7 and 8 are R 1 and R 2 respectively, a ratio R 1 /R 2 =35/55, and the angle α will be 35 degrees, and the angle γ will be 90 degrees.
FIG. 5 shows a modification of the embodiment in FIG. 1, in which a pair of mutually engaged spur wheels 15 and 16 are provided on the main rudder member 1 at the top end thereof. Vertical center lines of spur wheels 15, 16 are located in the fore and aft vertical center line plane XX with the spur wheel 15 engaged with the teeth 27 of sector member 24 and with the spur wheel 16 engaged with the teeth 28 of guide member 25. 17 and 18 denote a pair of vertical pins supporting both spur wheels 15 and 16 respectively on the top end of the main rudder member 1. This modification will serve to reduce the size of the sector member 4 and the guide member 5 in case of fabricating a substantially large-sized rudder, and will operate in the same manner as the rudder arrangement in FIG. 1.
FIG. 6 shows another modification of the embodiment in FIG. 1, in which a pair of mutually engaged spur wheels 29, 30 are provided on the main rudder member 1 at the top end thereof. A vertical center line of both spur wheels 29, 30 is located in a vertical plane PP at an angle θ with respect to the fore and aft vertical center line plane XX, with the spur wheel 29 engaged with the sector member 24 and with the spur wheel 30 engaged with the guide member 25. This embodiment will serve to prevent both spur wheels 15 and 16 in the modification in FIG. 5 from becoming excessively small, and also serve to enable a pair of mutually engaged spur wheels 29 and 30 of standard size to be used at all times between the sector member 4 and the guide member 5 by regulating the angle of θ even though a distance D between the rudder stock 3 and the pivot pins 11A, 11B is changed. 31, 32 denote a pair of vertical pins supporting both spur wheels 29 and 30 respectively on the top end of the main rudder member 1. This modification will operate in the same manner as the rudder arrangement in FIG. 1.
As described hereinabove, according to the present invention, only a single piece of sector member 4 or a sector member 24 together with a pair of small intermediate wheels in case of large-sized rudders, are provided as a moving part in a very restricted space between the hull structure and the top end of the main rudder member, and hence the cost of construction and maintenance will be considerably reduced and will improve the reiliability of operation. | A ship's rudder having a flap at its trailing end, actuating apparatus for such flap comprises a sector member which is mounted on the flap at top end thereof, extending toward a rudder stock and has teeth concentric with pivot pins mounting the flap on the rudder and engaged with teeth arranged concentrically with a rudder stock on a stationary guide member surrounding the rudder stock. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The subject matter described in this application is related to subject matter disclosed in the following commonly assigned applications: U.S. patent application Ser. No. 14/223,011 (now U.S. Pat. No. 9,402,638), filed Mar. 24, 2014, entitled “CUTTING BURR SHANK CONFIGURATION,” and U.S. patent application Ser. No. 13/082,016 (now U.S. Pat. No. 8,690,876), filed on Apr. 7, 2011, entitled “CUTTING BURR SHANK CONFIGURATION,” which are incorporated herein by reference in their entirety.
BACKGROUND
When performing surgery, surgeons may utilize a surgical drilling instrument for drilling, cutting or shaping bones that utilize a numerous different kinds and sizes of cutting burrs and attachments. During certain medical operations, the cutting burr needs to be changed. The change must be done timely and efficiently in view of the surgical demands. To this end, the portion of the cutting burr, namely, the proximate end of the shank typically lacks a configuration to accommodate this change of the cutting burr.
SUMMARY
Disclosed herein is a cutting burr that provides for a quick release that is fast and simple, and which facilitates the insertion of the cutting burr into a surgical drilling instrument. The cutting burr may have a pair of axially spaced six sided diamond-shaped portions, where one diamond-shaped portion may be formed at an edge of the proximal end of the cutting burr and provides a positive connection with a drive spindle that is connected to a drive motor of the surgical drilling instrument. A second, axially disposed diamond-shaped portion is adapted to mate with a locking pawl of the surgical drilling instrument. The locking pawl engages the axially disposed diamond-shaped portion to lock the cutting burr into the surgical drilling instrument with substantially no axial movement.
In some implementations, a detent pawl is provided to hold the cutting burr within the surgical instrument when it is in a loading position. The detent pawl may engage the axially disposed diamond-shaped portion at a side opposite the locking pawl.
In some implementations, the diamond-shaped portion at the proximal end is sized such that it can be used with older surgical drilling instruments that may not be provided with a complementary receiving recess for the diamond-shaped portion.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary is better understood when read in conjunction with the appended drawings. For the purposes of illustration, there is shown in the drawings exemplary implementations; however, these implementations are not limited to the specific methods and instrumentalities disclosed. In the drawings:
FIG. 1 a fragmentary top plan view illustrating the axially spaced six-sided diamond-shaped cut out portion or portions formed on the proximate end of the shank of the cutting burr;
FIG. 2 is a perspective view of FIG. 1 ;
FIG. 3 is another prospective view of FIG. 1 slightly turned illustrating one of the facets in each of the six-sided diamond-shaped portions;
FIG. 4 is another perspective view of FIG. 2 slightly turned illustrating the top facets of the six-sided diamond-shaped portions;
FIG. 5 is an end view taken along lines 5 - 5 of FIG. 3 illustrating the shape of the six-sided diamond-shaped portion formed in the cutting burr shank;
FIG. 6 is a sectional view taken along lines 6 - 6 of FIG. 4 illustrating the shape of the six-sided diamond-shaped portion and illustrating the different sizes and the orientation of the six-sided diamond portion formed in the cutting burr shank;
FIGS. 7A and 7B illustrate a backwards compatibility of the cutting burr of FIGS. 1-6 within a receiving portion of conventional surgical drill;
FIGS. 8A and 8B illustrate a self-alignment aspect of the diamond-shaped portion at a proximal end of the cutting burr in relation to a keyed slot of a surgical drill;
FIG. 9 is an elevated view of the cutting burr with a spherical shaped cutting bit illustrating the diamond-shaped portions formed in the shank thereof;
FIG. 10 is another elevated view of an example cutting burr; and
FIG. 11 is another elevated view of an example cutting burr.
DETAILED DESCRIPTION
As used herein, the term “cutting burr” may be analogous with terms such as bit, drill bit, surgical drill bit and the like. The term “attachment” may have several meanings within the text of this application, but when generalized as a component of a surgical drilling instrument it refers to a portion of the instrument that attaches to the end of the motor/locking mechanism and receives the cutting burr. An “attachment” may be a controlled depth attachment, a minimally invasive attachment and the like. The surgical drilling instrument may include an integral motor (electric or pneumatic) and a locking mechanism and an attachment releasably connected to the locking mechanism.
High speed surgical drills are increasingly being used by surgeons when performing delicate bone dissection in areas such as the cervical and lumbar spine. Such surgical drills operate at very high R.P.M., and are able to rotationally drive multiple types of attachments and cutting burrs. As will be described below, a cutting burr of the present disclosure includes a shank that defines two substantially diamond-shaped portions. The substantially diamond-shaped portions provide for ease of insertion and removal of the cutting burr to and from a compatible surgical drill. The substantially diamond-shaped portions also enable the surgical drill to direct higher levels of torque to the cutting burr during surgical procedures.
Referring to FIGS. 1-6 , the cutting burr is generally illustrated by reference numeral 10 . The attachment portion 12 of the shank 16 of the cutting burr 10 is generally shown as reference numeral 12 . A proximal end 14 of the shank 16 is formed with a pair of axially spaced six-sided diamond-shaped portions 18 and 20 . As shown in FIGS. 4 and 5 , an upper surface of portion 18 includes an apex 32 and a pair of facets 34 and 34 a also fairing to side edges 34 b and 34 c . The side edges 34 b and 34 c may be curved to match the radius of curvature of an outer surface of the shank 16 . As shown in FIGS. 4 and 6 , an upper surface 24 of the portion 20 includes apex 26 and a pair of facets 30 and 30 a fairing from the apex 26 to the side edges 30 b and 30 c . The side edges 30 b and 30 c may be curved to match the radius of curvature of an outer surface of the shank 16 .
As shown in the Figs. the diametrical dimensions of the vertices in both portions is less than the diameter of the main body of the shank. The shank 16 may include an annular groove 29 . The lower surfaces of the pair of six-sided diamond portions 18 and 20 are a mirror image of the upper surface. While the diamond-shaped portions 18 and 20 are described as being “diamond-shaped,” it is noted that such terminology is intended to encompass any six-sided (hexagon) shape having a cross-section with flat edges that meet at a six vertices, curved edges that meet at six points, or some combination of both to form the six sides. The flat and curved edges, and combinations thereof, may be applied to other polygon shapes having different numbers of sides.
The diamond-shaped portion 18 at the outermost proximal end is designed to be inserted into a mating drive portion of a surgical drill, as will be described with reference to FIGS. 8A and 8B . The diamond-shaped portion 20 is provided as an abutment surface of a retractable locking pawl of the surgical drill to provide axial locking of the shank 16 within the surgical drill. The locking pawl may axially abut the adjacent abutment surface of the diamond-shaped portion 20 to axially lock the cutting burr 10 in place, thus providing substantially zero axial movement. For example, an engagement portion of locking pawl may be contoured having a generally V-shape with inner surfaces that fit against the facets 30 and 30 a of the diamond-shaped portion 20 .
As shown in FIG. 3 , a back wall 42 may be formed perpendicular with relation to the central line A and faces a front wall 40 that is tapered from the facet (e.g., 30 a ) to the outside diameter of the shank 16 . In accordance with some aspects, an engagement face of the locking pawl may abut against the back wall 42 to provide axial locking of the cutting burr 10 within the surgical drill. A tapered front wall 40 may facilitate the engagement of the locking pawl into the diamond-shaped portion 20 .
The diamond-shaped portion 20 may also be engaged by a detent pawl of the surgical drill. For example, an engagement end of detent pawl may be contoured, e.g., having a generally hill shape to partially fit into the diamond-shaped portion 20 on an opposite side of the engagement end of the locking pawl. The detent pawl may be provided to apply a sufficient force on the diamond-shaped portion 20 to allow the cutting burr 10 to be moved in and out of the surgical drill, while reducing the likelihood that the cutting burr will inadvertently fall out of the surgical drill when in a loading position.
As shown by the a comparison of the sectional views of the diamond-shaped portions 18 and 20 ( FIGS. 5 and 6 ), the two diamond shapes may be different in size, where the diamond shape in diamond-shaped portion 18 is larger than the diamond shape of the diamond-shaped portion 20 . As illustrated, the vertices 32 and 36 fall below the outer diameter of the shank 16 and both diamond shapes are in axial alignment with each other and may be oriented in parallel relationship. In some implementations, the diamond-shaped portion 20 and the diamond-shaped portion 18 may be the same size, or the diamond-shaped portion 18 may be larger than the diamond-shaped portion 20 . In the various configurations, the vertices 26 and 32 of diamond-shaped portions 20 and 18 , respectively, are along a same line and in a same plane as the center line A. Exemplary dimensions of the six-sided diamond diamond-shaped portions 18 and 20 are listed in degrees (°) and inches (″) and may be substantially as follows:
The angle of the facets of the six-sided diamond in the diamond-shaped portion 20 —a=47°;
The width of the facets of the six-sided diamond in the diamond-shaped portion 20 —b=0.046″;
The width of the facets of the six-sided diamond in the diamond-shaped portion 18 —c=0.065″;
The width of the shank 16 at the space between diamond-shaped portions 18 and 20 —d=0.029″;
The length of the diamond-shaped portion 20 —e=0.068″; and
The length between the proximal end and the back wall of diamond-shaped portion 18 f=0.149″. This dimension may contribute to the feature of substantially reducing the axial play of the cutting burr.
Thus, in accordance with the above, the diamond-shaped portions 18 and 20 provide sufficient cross-sectional dimensions to meet strength and reliability requirements needed for high-speed, large force surgical applications. Facets 34 and 34 a of the diamond shape 18 provide positive engagement surfaces in both clockwise and counter-clockwise rotational directions and are sufficiently sized to withstand rotations forces in either direction without wobbling within the surgical drill. For example, some surgical drills provide bi-directional rotation, allowing the surgeon to selectively reverse rotation for various surgical techniques. In conventional designs, there may be rotational play between a bit end and a drive portion. However, the symmetrical diamond facets 34 and 34 a of the diamond-shaped portion 18 provide substantial drive surfaces in either direction.
With reference to FIGS. 7A and 7B , the diamond-shaped portion 18 at the outermost proximal end of the cutting burr 10 is designed to have unidirectional backward compatibility with older drill instruments in accordance with aspects of the disclosure. For example, a conventional drill instrument may include an insert 106 that defines a generally rectangular slot 105 having rounded side walls. The rounded side walls may be shaped with a radius of curvature that parallels the outer wall of the insert 106 . Conventional cutting burrs may include a complementary generally rectangular portion having rounded side walls that is received by the slot 105 . The insert 106 may be driven by a motor, thus providing rotational force on the cutting burr.
As shown in FIG. 7A , in accordance with some implementations, facets 34 a and 34 d of the diamond-shaped portion 18 engage the inner walls of the slot 105 . The dimension c of the diamond-shaped portion 18 , noted above, may be sized such that the surface area of the facets 34 a and 34 d is substantial enough to withstand the torque provided by the motor of the conventional drill instrument. Thus, the cutting burr 10 of the present disclosure may be utilized by conventional drill instruments.
Referring now to FIGS. 8A and 8B , in some implementations, the cutting burr 10 of the present disclosure provides for a level of self-alignment within the insert 106 . The insert 106 may be provided in a compatible surgical drill and define a diamond-shaped key slot 107 , a pointed shaped inlet end 109 , and opposing holes 110 that formed in the insert 106 for receiving dowel pin which may serve to locate the cutting burr 10 when inserted into the key slot 107 . The inlet end 109 serves to facilitate the alignment and insertion of the cutting burr 10 as it is advanced toward and into the key slot 107 of the insert 106 . For example, if the diamond-shaped portion 18 is not in alignment with the key slot 107 ( FIG. 8A ), a bottom surface of the diamond-shaped portion 18 will contact an apex 111 of the inlet end 109 causing the cutting burr 10 to rotate into alignment with the key slot 107 . As such, the cooperative engagement of the diamond-shaped portion 18 and inlet end 109 facilitates the easy insertion of the cutting burr 10 into the compatible surgical drill. As such, the diamond portion 18 serves to provide a secure connection in the key slot 107 .
FIGS. 9, 10, and 11 illustrate different example cutting bits 22 provided at a distal end on the shank 16 . As described above, the shank 16 may include the attachment portion 12 . The cutting bits 22 may be milled or cut-out portions. The cutting burr 10 in FIG. 9 exemplifies a fluted ball or drill bit; the cutting burr 10 in FIG. 10 exemplifies a diamond ball; and the cutting burr 10 in FIG. 11 exemplifies a twist drill. The cutting bits 22 are presented only as examples and are not intended to limit the scope of the present disclosure as numerous variations are possible.
Thus, as described above, a cutting burr is provided with an attachment end that has a configuration and dimensions that serve to facilitate the insertion of the cutting burr into the surgical cutting instrument. When locked in the running position there is a structure that prevents the cutting burr from having any axial movement. Also, there is a positive connection such that the cutting burr rotates concentrically without any wobbling motion.
While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based on the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. | A cutting burr that includes a pair of axially spaced diamond-shaped portions designed to be keyed into a spindle of a locking mechanism of a high speed surgical drilling instrument and adapted to fit into a single pawl thereof to lock said cutting burr in place so as to prevent axial movement thereof and provide concentric rotation of said cutting burr without any wobbling. The orientation of both portions may be identical with respect to a center plan and diamond shape in the portion at the proximal end of the shank of the cutting tool may be larger than the intermediately located diamond shape of the other portion. The apexes of the facets of the six-sided diamond shape may be disposed below the surface of the shank of the cutting burr. | 8 |
This is a continuation-in-part of our pending U.S. patent application Ser. No. 06/743,573 filed June 11, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the servicing of wells by use of coil tubing and more particularly to removal of scale and other downhole deposits from the inside diameter of well tubulars.
2. Description of the Prior Art
It has been common practice for many years to run a continuous reeled pipe (known extensively in the industry as "coil tubing") into a well to perform operations utilizing the circulation of treating fluids such as water, oil, acid, corrosion inhibitors, cleanout fluids, hot oil, and the like fluids. Coil tubing being continuous, rather than jointed, is run into and out of a well with continuous movement of the tubing through use of a coil tubing injector.
Coil tubing is frequently used to circulate cleanout fluids through a well for the purpose of eliminating sand bridges, scale, or other downhole deposit obstructions. Often such obstructions are very difficult and occasionally impossible to remove because of the inability to rotate the coil tubing to drill out such obstructions. Turbo-type drills have been used but have been found to develop insufficient torque for many jobs.
Thus, it is desirable to perform drilling operations in wells through use of coil tubing which can be run into and removed from a well quickly in addition to performing the usual operations which require only the circulation of fluids.
U.S. Pat. No. 3,285,485 which issued to Damon T. Slator on Nov. 15, 1966 discloses a device for handling tubing and the like. This device is capable of injecting reeled tubing into a well through suitable seal means, such as a blowout preventer or stripper, and is currently commonly known as a coil tubing injector.
U.S. Pat. No. 3,313,346 issued Apr. 11, 1967 to Robert V. Cross and discloses methods and apparatus for working in a well using coil tubing.
U.S. Pat. No. 3,559,905 which issued to Alexander Palynchuk on Feb. 2, 1971 discloses an improved coil tubing injector.
High pressure fluid jet systems have been used for many years to clean the inside diameter of well tubulars. Examples of such systems are disclosed in the following U.S. Pat. Nos.:
______________________________________3,720,264 3,850,241 4,442,8993,811,499 4,088,1913,829,134 4,349,073______________________________________
Outside the oil and gas industry, tubing cleaners have been used for many years to remove scale and other deposits from the inside diameter of tubes used in heat exchangers, steam boilers, condensers, etc. Such deposits may consist of silicates, sulphates, sulphides, carbonates, calcium, and organic growth. Tubing cleaners and associated equipment are disclosed in Elliot tubing cleaners bulletin Y-100 1580F-second edition. This bulletin is incorporated by reference for all purposes within this application. Elliot Company is a division of Carrier Corporation, a subsidiary of United Technologies Corporation.
The preceding patents are incorporated by reference for all purposes within this application.
SUMMARY OF THE INVENTION
The present invention is directed towards improved methods and apparatus for cleaning well tubulars using coil tubing.
One object of the invention is to provide a high speed, fluid-powered cutter head to remove scale and other deposits from the inside diameter of a well tubular.
Another object of the present invention is to provide guide means to prevent the cutter head from becoming fouled with other downhole well tools.
A further object of the present invention is to provide sleeve means to centralize the universal joint connecting the fluid motor with the cutter heads and avoid fouling with downhole tools.
A still further object of the present invention is to provide a combination cutter and guide means with improved ability to remove all types of downhole deposits.
Additional objects and advantages of the present invention will be readily apparent to those skilled in the art after studying the written description in conjunction with the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing partially in elevation and partially in section with portions broken away showing a coil tubing unit and tubing cleaner removing deposits from the inside diameter of a well tubular.
FIG. 2 is an enlarged drawing partially in section and partially in elevation showing guide means to prevent the tubing cleaner from becoming fouled with other downhole well tools.
FIG. 3 is schematic drawing partially in elevation and partially in section showing alternative guide means to prevent the tubing cleaner from becoming fouled with other downhole well tools.
FIG. 4 is a schematic drawing partially in elevation and partially in section with portions broken away showing a tubing cleaner having a fluid motor, hose, and cutter/guide means.
FIG. 5 is an enlarged schematic drawing partially in elevation and partially in section with portions broken away showing a guide means with an alternative fluid flow path.
FIG. 6 is drawing in section taken along line 6--6 of FIG. 5.
FIG. 7 is a schematic drawing in elevation showing a tubing cleaner with guide means attached thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 well 20 extends from wellhead 21 to an underground hydrocarbon or fluid producing formation (not shown). Well 20 is defined in part by casing string or well flow conductor 22. This embodiment will be described with respect to casing 22. However, the present invention can be used with other types of well tubulars or flow conductors including liners and production tubing strings. Also, the present invention is not limited to use in oil and gas wells.
During the production of formation fluids, various types of deposits may accumulate on the inside diameter of the well tubulars. Examples of soft deposits are clay, paraffin, and sand. Examples of hard deposits are silicates, sulphates, sulphides, carbonates and calcium. The present invention is particularly useful for removal of hard deposits found in some geothermal and oil wells but may be satisfactorily used to remove other types of deposits.
Using conventional well servicing techniques, injector 25 can be mounted on wellhead 21. Continuous or coil tubing 26 from reel 27 is inserted by injector 25 into bore 23 of casing 22. Tubing cleaner assembly 39 is attached to the lower end of coil tubing 26. Manifold 28 includes the necessary pumps, valves, and fluid reservoirs to discharge power fluid into bore 23 via coil tubing 26. Valves 29 and 30 can be used to control the return of spent power fluid to the well surface.
Fluid motor 40 is attached to the extreme end of coil tubing 26 disposed in casing 22. Fluid motor 40 is mechanically connected to cutter heads 42 by universal joint 41. Motor 40, universal joint 41, and cutter heads 42 are commercially available from Elliot Company. Deposits 36 can be removed from the inside diameter of casing 22 by inserting coil tubing 26 with tubing cleaner assembly 39 including motor 40 and cutter head 42 attached thereto to the desired downhole location. Power fluid from manifold 28 is supplied to motor 40 via coil tubing 26 to rotate cutter heads 42 at a relatively high rate of speed. High speed is particularly useful in removing hard deposits. Power fluid discharged from motor 40 is returned to the well surface via valves 29 or 30.
Many well completions have deviated well tubulars and/or downhole well tools which might restrict longitudinal movement of cutter head 42 throughout the length of the well bore. An example of such a tool is a side pocket gas lift mandrel (not shown). This downhole tool typically has a main bore extending longitudinally therethrough compatible with the bore of the well tubular. A second, smaller bore is offset from the main bore to provide a receptacle for gas lift valves. Cutter heads 42 might become fouled in this offset bore. An example of a side pocket mandrel is shown in U.S. Pat. No. 4,333,527 incorporated by reference for all purposes within this application.
FIGS. 2 and 3 show guide means 50 which can be attached to cutter heads 42 by flexible shaft 51 and universal joint 52. Preferably, flexible shaft 51 extends downwards from cutter heads 42 with guide means 50 positioned therebelow. Guide means 50 is selected to be compatible with the main bore of the well tubular which cutter heads 42 will clean but larger than any offset bore or potential restriction that cutter head 42 might encounter downhole. Thus, guide means 50 will prevent the fouling of cutter head 42 in such restrictions.
Depending upon the type of deposit to be cleaned and other downhole conditions, universal joint 52 may be subject itself to fouling in other downhole tools. In FIG. 2, rubber sleeve 53 is disposed around universal joint 52 to centralize joint 52 and the tools attached thereto while being lowered through well flow conductor 22. When motor 40 is operating, sleeve 53 allows limited flexing of joint 52. In FIG. 3, spring 54 is disposed around the exterior of universal joint 52 for this same purpose. The use of either rubber sleeve 53 or spring 54 will be contingent on the anticipated downhole environment.
Guide means 50 will rotate due to the mechanical connection with cutter head 42 by flexible drive shaft 51. Teeth or serrations 55 may be formed on the exterior of guide means 50 to initially remove a portion of deposits 36 prior to engagement by cutter head 42.
ALTERNATIVE EMBODIMENT
An alternative tubing cleaner assembly 139 is shown in FIG. 4 attached to the lower end of coil tubing 26. Tubing cleaner assembly 139 includes fluid motor 140, hose 70 and combination cutter/guide means 150. Fluid motor 140 preferably includes two fluid-powered turbines 141 and 142 to take maximum advantage of the energy available in the power fluid supplied by coil tubing 26. Power fluid flows from coil tubing 26 through multiple ports 143 and contacts first turbine 141. Power fluid continues through fixed stator 144 and then contacts second turbine 142. A plurality of openings 145 are provided in hollow drive shaft 146 to allow spent power fluid to exit from second turbine 142. Various bearings 191, 192, and 193 are provided in motor 140 to allow rotation of drive shaft 146 and attached turbines 141 and 142. Some components in motor 140 are commercially available from various sources including the Elliot Company.
Flexible hose 70 is attached to hollow drive shaft 146 by threaded connection 71. Hose 70 and combination cutter/guide means 150 rotate in unison with drive shaft 146. Cutter/guide means 150 is similar to previously described guide means 50. The principal differences are flow path 151 and exit ports 152 and 153 which allow spent power fluid to flow from hose 70 through cutter/guide means 150. Serrations 155 are provided on the exterior of cutter/guide means 150 to remove deposits from the interior of well flow conductor 22. The efficiency of serrations 155 is greatly increased by having spent power fluid from exit ports 152 flow upwardly therepast. The power fluid flow path of tubing cleaner assembly 139 optimizes both the rotational effect of serrations 155 and the lifting of loosened deposits by spent power fluid to the well surface. For well cleaning operations involving soft deposits, exit ports 152 can be designed to produce a jetting effect as spent power fluid leaves guide means 150. This jetting effect will remove soft deposits before they can foul serrations 155.
Hose 70 may be selected from many commercially available products including flexible steel hoses as well as elastomeric hoses. Hose 70 must be selected to withstand wear on its exterior associated with rotating inside well flow conductor 22.
An alternative cutter/guide means 250 is shown in FIG. 5. Cutter/guide means 250 is attached to and rotated by hose 70 in the same manner as previously described cutter/guide means 150. Cutter/guide means 250 includes mandrel means 252, end cap 253, housing means 270, and serrations 255. Mandrel means 252 has flow path 251 extending partially therethrough with threads 259 formed in flow path 251 to allow attachment of cutter/guide means 250 to hose 70. Flow path 251 extends only partially through the length of cutter/guide means 250 as compared to flow path 151. A plurality of ports 280 extend radially from flow path 251 above serrations 255.
Housing means 270 is disposed around the exterior of mandrel means 252 and covers ports 280. Annular chamber 271 is formed between the exterior of mandrel means 252 and the interior of housing means 270 to receive spent power fluid from ports 280. As best shown in FIG. 6, a portion of the exterior of housing means 270 has been removed by machining longitudinal groove 273 partially therethrough. A plurality of openings 272 extend from groove 273 to tangentially intersect chamber 271. Groove 273 has surfaces 273a and 273b perpendicular to each other. Openings 272 are machined normal to surface 273b. The result is that spent power fluid can flow from hose 70 through flow path 251 and ports 280 into annular chamber 271. Openings 272 allow spent power fluid to exit from chamber 271 at a tangent relative to the outer surface of mandrel means 252. Exhausting spent power fluid in this manner will cause increase oscillation of cutter/guide means 250 within well flow conductor 22. Openings 272 can also be designed to produce a jet spray as power fluid exits housing means 270. A jet spray may be desirable to remove soft deposits.
Serrations 255 are shown disposed on the exterior of mandrel means 252 below housing means 270. The relative longitudinal position of serrations 255 and housing means 270 could be modified as taught by cutter/guide means 150. End cap 253 is used to hold serrations 255 and housing means 270 on the exterior of mandrel means 252.
The previous description is illustrative of only some embodiments of the present invention. Those skilled in the art will readily see other variations and modifications without departing from the scope of the invention as defined in the claims. | A system for cleaning wells with coil tubing, a fluid motor and cutter heads. The invention allows equipment used to clean boiler tubes or heat exchangers to effectively remove downhole deposits from the inside diameter of well tubulars. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to human body attachable apparatus for transporting items, and more specifically an apparatus to assist in the organization and delivery of such items.
BACKGROUND
[0002] For purposes of this application, the items of the present invention is discussed and described in reference to postal matter, or mail, but the present invention can be used for any object, article, or thing.
[0003] For purposes of this application, the present invention is discussed and described in reference to a mail carrier, but the present invention is applicable to any user.
[0004] Every person who delivers mail, referred to herein as a “mail carrier” or simply “carrier”, has to organize and maintain a variety of mail types for delivery to address points. The first type is “working mail”, which includes magazine flats, large envelopes, and may also include smaller envelopes. The second type of mail is “delivery point sequence” or “direct point sequence” (“DPS”). Working mail and DPS mail is machine sorted and provided to carriers in presorted bundles and typically provided to the carriers in order of delivery. The third type of mail is known as “coverage”, which includes sales papers, catalogs, or brochures. Coverage mail is typically delivered to each and every address point. The fourth type of mail is known as “accountables”, and includes certified mail, insured mail, registered mail, signature confirmation mail, and express mail. The fifth and last type of mail is “packages” which are boxes or parcels of different weight and size. Coverage, accountables, and packages are typically hand sorted. All types of mail that carriers maintain, organize and deliver is collectively referred to herein as “postal matter”.
[0005] Normally, the carrier collates postal matter for an address point with the use of both hands and both arms. Typically, a carrier uses a first hand to sort through working mail whereupon the selected working mail is cradled with the carrier's second arm. The carrier again uses the first hand to sort through DPS mail whereupon the selected DPS mail is held in the carrier's second hand. Thus, the carrier simultaneously cradles the selected working mail with the second arm and holds the selected DPS mail in the second hand. The first hand is also used to sort and select coverage mail, accountables, and packages, which are typically located within the carrier's mail bag or satchel, for delivery to the address point.
[0006] This method requires coordination, balance, and full use of two hands and an arm and considered by some to be uncomfortable, inefficient, and unstable. This method is not only time consuming, but also may subject the mail carrier to a risk of injury.
[0007] Devices for carrying mail exist, but they do not adequately address all of the needs of the carrier. For example, U.S. Pat. No. 5,836,488 is a device that must be strapped on the forearm between the elbow and the hand of the carrier and has two compartments. U.S. Patent Application No. 2006/0000857 is a device with two compartments that is also supported on the forearm. These devices are deficient in several respects, for example, they require support by the forearm and fail to provide use of both arms simultaneously.
[0008] There is a need for an apparatus that assists a mail carrier in the organization and delivery of postal matter. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0009] The present invention is an apparatus for assisting a mail carrier with organizing and delivery of postal matter. According to the present invention, the apparatus does not require support by one or more arms. This apparatus contemplates simple, stable collation requiring only one hand, thus enabling those who only have the use of one arm or hand to effectively deliver mail and enable those who have the use of two arms or hands to do so with greater ease and efficiency. The apparatus may decrease the risk of injury to the carrier, which is a substantial benefit since many mail carriers experience or are at risk to develop arthritis or carpel tunnel syndrome.
[0010] One embodiment the present invention is an apparatus that comprises a working element, a first support element and a securing element.
[0011] The working element may be any size or shape and constructed from any material in order to provide a surface for maintaining postal matter. The first support element secures the apparatus, more specifically, the working element to a body of a carrier. For example, the first support element is positioned substantially about the neck or shoulders of a carrier such that the working element remains level. The first support element is connected to the working element via a first connecting element. The securing element is positioned on the top surface of the working element and may be constructed of any material such that the securing element secures postal matter on the top surface of the working element. It is further contemplated that the securing element may have elastic properties to be easily manipulated by the carrier. Any number of securing elements is contemplated.
[0012] In another embodiment of the apparatus includes a holding element and yet another embodiment of the apparatus further includes a retaining element. The holding element and retaining element are positioned along a side of the working element and may be any size or shape and constructed from any material in order to hold or retain postal matter.
[0013] The holding element and retaining element may be any size, shape and constructed from any material to hold postal matter. Also, any number of holding elements and retaining elements are contemplated.
[0014] In yet another embodiment of the present invention, the apparatus further includes a second support element connected to the working element via a second connecting element. The second support element further secures the apparatus to the body of a carrier. For example, the second support element is positioned substantially about the waist of a carrier such that the working element remains level.
[0015] The first support element and second support element may be, for example, a strap, strip, harness or lanyard made of any material such as plastic, leather, or fabric. The first support element and second support element may further be adjustable to accommodate various positions of the working element with respect to the body of a carrier such that the apparatus is comfortable. It is also contemplated that in certain embodiments the first support element is attached to the second support element.
[0016] The first connecting element and second connecting element may be anything to connect the first support element and second support element, respectively, to the working element. For example, the first connecting element and second connecting element may be adhesive, weld, brackets, anchors, or hooks, to name a few.
[0017] In yet another embodiment of the present invention, the apparatus further includes accessories. Accessories may include, for example, an umbrella, a lighting device, or animal repellant. It is contemplated that the accessories may be easily removable or securely affixed to the apparatus.
[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.
DRAWINGS
[0019] FIG. 1 is a perspective view of one embodiment of the apparatus according to the present invention;
[0020] FIG. 2 is a perspective view of another embodiment of the apparatus according to the present invention;
[0021] FIG. 3 is perspective view of yet another embodiment of the apparatus according to the present invention;
[0022] FIG. 4 is perspective view of yet another embodiment of the apparatus according to the present invention;
[0023] FIG. 5 is perspective view of yet another embodiment of the apparatus according to the present invention;
[0024] FIG. 6 is perspective view of yet another embodiment of the apparatus according to the present invention;
[0025] FIG. 7 is perspective view of yet another embodiment of the apparatus according to the present invention;
[0026] FIG. 8 is perspective view of yet another embodiment of the apparatus according to the present invention; and
[0027] FIG. 9 is perspective view of an embodiment of the apparatus worn by a carrier according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] For purposes of this application, the items of the present invention are discussed and described in reference to postal matter, or mail, but the present invention can be used for any object, article, or thing.
[0029] FIG. 1 is a perspective view of an embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 10 comprises a working element 100 , a first support element 200 and a securing element 300 . The working element 100 is a rectangular aluminum platform 102 and includes a top surface 104 , bottom surface 106 , a first side boundary 108 , a second side boundary 110 , a third side boundary 112 , and a fourth side boundary 114 . The first support element 200 includes a first end 204 and a second end 206 , and is shown in FIG. 1 as a strap 202 . A first connecting element 400 , here a bracket 402 , connects the strap 202 to the platform 102 . The first connecting element 400 is positioned on the top surface 104 of the working element 100 . The ends 204 , 206 of the first support element 200 connect to the first connecting element 400 such that the first support element 200 may be positioned substantially about the neck of a carrier. The securing element 300 includes a first edge 304 and a second edge 306 and is positioned on the top surface 104 of the working element 100 . The first edge 304 of the securing element 300 connects to the first side boundary 108 of the working element 100 and the second edge 306 of the securing element 300 connects to the second side boundary 110 of the working element 100 . The securing element 300 is shown as an elastic band 302 .
[0030] FIG. 2 is a perspective view of another embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 20 further comprises a holding element 500 . Holding element 500 is positioned on the third side boundary 112 of the working element 100 , although the holding element 500 may be positioned on any side boundary 108 , 110 , 114 of the working element 100 . As shown in FIG. 2 , holding element 500 is a plurality of grasping components 502 .
[0031] FIG. 3 is a perspective view of another embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 30 further comprises a retaining element 600 . Retaining element 600 is positioned on the second side boundary 110 of the working element 100 , although the retaining element 600 may be positioned on any side boundary 108 , 112 , 114 of the working element 100 . As shown in FIG. 2 , retaining element 600 is a bin 602 .
[0032] FIG. 4 is perspective view of yet another embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 40 includes a second support element 250 with a first ending 254 and a second ending 256 , and is shown in FIG. 4 as an adjustable belt 252 . A second connecting element 450 , here adhesive 452 , connects the adjustable belt 252 to working element 100 . Specifically, the second connecting elements 450 are positioned on the fourth side boundary 114 of the working element 100 . The endings 254 , 256 of the second support element 250 connect to the second connecting element 450 such that the second support element 250 may be positioned substantially about the waist of a carrier such that the working element 100 remains level.
[0033] FIG. 5 is a perspective view of another embodiment of the apparatus of FIG. 4 according to the present invention. In this embodiment, the apparatus 50 further comprises a holding element 500 . Holding element 500 is positioned on the first side boundary 108 of the working element 100 . Here, the holding element 500 is a basket 504 .
[0034] FIG. 6 is a perspective view of another embodiment of the apparatus of FIG. 4 according to the present invention. In this embodiment, the apparatus 60 further comprises a retaining element 600 . Retaining element 600 is positioned on the third side boundary 112 of the working element 100 . Here, the retaining element 600 is a container 604 .
[0035] FIG. 7 is perspective view of yet another embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 70 includes a working element 100 , a securing element 300 , a holding element 500 , and two retaining elements 600 . The first edge 304 of the securing element 300 connects to the first side boundary 108 of the working element 100 and the second edge 306 of the securing element 300 connects to the second side boundary 110 of the working element 100 such that the securing element 300 is positioned on the top surface 104 of the working element 100 . The securing element 300 is shown as a spring band 308 . Holding element 500 , shown as a receptacle 506 , is positioned on the first side boundary 108 of the working element 100 . Retaining elements 600 are positioned on the second side boundary 110 and third side boundary 112 of the working element 100 . As shown, retaining element 600 on the second side boundary 110 is a receptacle 606 and retaining element 600 on the third side boundary 112 is a receptacle 608 .
[0036] As shown in FIG. 7 , the first support element 200 is attached to the second support element 250 . The first support element 200 is a lanyard 208 and the second support element 250 is a harness 258 . A first connecting element 400 positioned on the top surface 104 of the working element 100 connects the lanyard 208 to the working element 100 . A second connecting element 450 positioned on the fourth boundary 114 of the working element 100 connects the harness 258 to the working element 100 . A third connecting element 260 connects the first support element 200 to the second support element 250 . More specifically, weld 262 connects the lanyard 208 and harness 258 .
[0037] FIG. 8 is perspective view of yet another embodiment of the apparatus according to the present invention. In this embodiment, the apparatus 80 includes accessories 700 . As shown in FIG. 8 , accessories 700 include an umbrella 702 , a lighting device 704 , and animal repellant 706 attached to the working element 100 , although it is contemplated that the accessories may be attached to the securing element 300 , holding element 500 or retaining element 600 . According to this embodiment, the umbrella 702 is attached to the first side boundary 108 of the working element 100 to protect the carrier from various weather elements, for example, sun and rain. Lighting device 704 is attached to the top surface 104 of the working element 100 to provide illumination. Animal repellant 706 is attached to the bottom surface 106 of the working element 100 in the event the carrier must combat aggressive animals.
[0038] FIG. 9 is perspective view of the apparatus of FIG. 8 worn by a carrier according to the present invention. In this embodiment, the carrier places the second support element 250 over the shoulders.
[0039] As an example, the carrier can organize postal matter by collating working mail, DPS mail, coverage mail, accountables, and packages in order to transport and deliver the postal matter. As an example, a carrier that only has use of one arm may use the present invention by placing all working mail in the holding element of the apparatus and placing all DPS mail in the retaining element of the apparatus. Any coverage, accountables or packages would remain in the mail carrier's satchel. The mail carrier uses the present invention to collate all mail for delivery to an address point: any coverage mail is pulled from the satchel and placed in the securing element; any working mail is grabbed from the holding element and placed in the securing element; and any DPS mail is grabbed from the retaining element and placed in the securing element. The mail carrier grabs the collated mail in the securing element and delivers it to the address point. Any accountables or packages are also delivered. This example is for illustrative purposes only—any type of mail may be placed in any of the securing, holding, or retaining element according to the present invention, and any order of collation is contemplated.
[0040] The working element as discussed herein, for example as a rectangular platform constructed from aluminum, is for illustrative purposes only. The working element may be any size or shape and constructed from any material in order to provide a light-weight surface for maintaining postal matter.
[0041] The first support element and second support element as discussed herein, for example as a strap, lanyard, and harness, is for illustrative purposes only. The support elements may be any size, shape, or material such as plastic, leather, rubber or fabric in order to secure the apparatus, more specifically the working element, to a body of a carrier such that the working element remains level. Additionally, the support elements may be adjustable.
[0042] The securing element is positioned on the top surface of the working element and is shown in the above referenced FIGS. as an elastic band and as a spring band, but may be constructed of any material such that the securing element is expandable or resilient or weighted in order for the securing element to secure postal matter.
[0043] The holding element and retaining element are positioned along a side of the working element and may be any size or shape and constructed from any material in order to hold or retain postal matter. For example, the holding element and retaining element may be a plurality of grasping components, bin, container, bag, barrel, basket, box, bucket, netting, cage, can, canister, capsule, crate, cup, holder, pouch, or receptacle.
[0044] The first connecting element, second connecting element, and third connecting element may be anything to connect the various elements of the apparatus, for example, adhesive, weld, brackets, anchors, or hooks, to name a few.
[0045] It will be understood that the embodiments of the present invention, which have been described, are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | The present invention is a human body attachable apparatus for assisting a user, such as a mail carrier, with organizing and delivery of items, for example postal matter. This apparatus contemplates simple, stable collation with one arm, thus enabling those who only have the use of one arm to effectively transport mail and enable those who have the use of two arms to do so with greater ease and efficiency. The apparatus includes a surface for maintaining items while also providing elements to secure, hold and retain items in order to organize, transport and deliver the items. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to dispensing cabinets and, more particularly, to dispensing cabinets having drawers of the type which are opened and closed under the control of a computer to control access to the contents of the drawer.
2. Description of the Background
In large medical facilities, inventories of medical supplies are normally held in centralized storage locations or pharmacies which are often far removed from decentralized storage locations. It is at the decentralized storage locations, e.g. a nurses station, that dispenses for patients are typically performed. To facilitate dispensing of medications and supplies for patients, a variety of dispensing systems have been proposed. For example, several dispensing systems have been proposed which employ a cart or cabinet which is located at the decentralized location.
Of particular interest to the present invention are dispensing systems which dispense pharmaceuticals and other items which require close monitoring and control. A variety of schemes have been proposed for providing secured access to pharmaceuticals that are held within such dispensing systems, including locking the pharmaceuticals within the carts or by allowing access to only one item at a time, commonly referred to as “single dose” or “unit dose” dispensing.
One such system is described in U.S. Pat. No. 5,014,875 titled “Medication Dispenser Station.” That system comprises a multiple-drawer cabinet for holding pharmaceuticals, with each drawer containing a covered, multiple-compartment carousel. Access to each drawer and each carousel compartment is controlled to allow access to the contents after a predetermined code or other information has been entered into a controller.
Another system is described in U.S. Pat. No. 4,847,764 titled “System for Dispensing Drugs in Health Care Institutions.” That dispensing system involves a computer system connected to a number of remote medication dispensers. The computer system includes software for, among other things, controlling access to the medications, identifying potentially dangerous drug interactions, and assisting with inventory control. The remote medication dispensers comprise a number of cabinets, with each cabinet holding a number of unit dose medication packages.
U.S. Pat. No. 5,927,540 titled “Controlled Dispensing System and Method” discloses apparatus and methods for dispensing articles in a controlled manner. In one embodiment, the invention provides an apparatus comprising a cabinet defining an enclosure. At least one drawer is attached to the cabinet and is configured to slide in and out of the cabinet. The drawer contains an array of compartments. At least one lid is attached to the drawer and is configured to slide forward and backward with respect to the drawer. Each drawer further includes a locking mechanism which may engage the lid at selective locations along the lid. With this arrangement, the locking mechanism may engage the lid to prevent movement of the lid relative to the drawer after a certain compartment has been exposed. Each drawer further includes a distance sensor for detecting the distance traveled by the lid relative to the drawer. A controller is placed in communication with both the locking mechanism and the distance sensor. The controller sends a signal to actuate the locking mechanism after the lid has been moved to expose a desired compartment. In that manner, the lid may be moved to allow access to a compartment containing a desired article or medical supply. The locking mechanism then engages the lid to prevent further movement of the lid, thereby preventing access to additional compartments.
U.S. Pat. No. 6,109,774 titled “Drawer Operating System” discloses a drawer operating system for allowing graduated access to consecutively spaced bins, partitioned in a drawer, so that access to the bins is controlled. The invention is housed in the rear of each drawer. It tracks the previous activity of the drawer and, when later accessed, allows the drawer to be pulled open to a length that will expose the contents of a bin either not emptied in previous openings or not uncovered in previous openings, retaining the other item-filled bins inside the cabinet and secure from access. In the preferred embodiment, the drawer is driven from its fully-closed position to a slightly-opened position of one inch or so to indicate to the user that this particular drawer may be opened further by merely pulling it outward. When the drawer is later pushed toward its closed position, it is stopped short of full closure and subsequently slowly driven closed into a locked position in the cabinet. This latter feature prevents “slamming” of the drawers into the cabinet and reduces the potential for damage to the contents therein.
While such systems provide for unit dose dispensing, the need exists for a unit dose dispensing cabinet that provides a means of accessing the medications in the event of a power failure or the need arises to override the computer controlling the cabinet. Additionally, it is desirable for the dispensing cabinet to be refilled or restocked in a convenient manner that reduces the likelihood that a restocking error will occur.
SUMMARY OF THE PRESENT INVENTION
One aspect of the present invention is a drawer for use in a dispensing cabinet. The drawer is comprised of a tray movable between an open position and a closed position. An insert, approximately the length of the tray, is carried by the tray and defines the volume of the drawer. A lockable lid, i.e., mechanically lockable or sealable with an adhesive seal, is carried by the insert. A release mechanism is provided to connect the insert to the tray in a manner that allows the insert to be easily disconnected from the tray. Removal of the insert enables inserts to be swapped so that inserts from which inventory has been depleted can be replaced with stocked inserts. Eliminating the need to transfer inventory from a restocking package to the insert eliminates the possibility of errors occurring from such a transfer.
Another aspect of the present invention is a dispensing cabinet having unit dose drawers of the type previously described. The dispensing cabinet comprises an input device, an output device and a computer connected to the input and output devices. A cabinet has a plurality of drawers, at least one of the drawers being a unit-dose dispensing drawer capable of dispensing a unit-dose. Each unit-dose dispensing drawer is comprised of a plurality of individual drawers, each individual drawer comprising a tray drivable between an open position and a closed position. An insert is carried by the tray. The insert defines one or more individual compartments each having a lockable lid. The insert is approximately the length of the tray and defines the volume of the drawer. A release mechanism is provided for connecting the insert to the tray. A self locking worm gear driven by a motor is connected to the tray through a clutch to provide a mechanism for driving the tray. During normal operation, the friction provided by the worm gear renders the drawers unmovable unless they are driven by the motor. In the event of a power failure or other problem, the clutch can be used to disengage the tray from the worm gear so that the drawers can be opened and closed.
Another aspect of the present invention is a method of restocking a unit dose drawer of a dispensing cabinet. The method is comprised of the steps of releasing a first insert that defines the volume of an individual drawer from a tray, connecting a filled insert to the tray from which the first insert has been removed, and unlocking or unsealing the lid of the filled insert. The first insert may then be delivered to a storage location for filling. After filling, the lid is locked and the filled first insert is delivered to a dispensing cabinet.
The present invention provides a convenient apparatus and method of refilling or restocking a dispensing cabinet in a manner that reduces the possibility of errors. The cabinet can be operated in such a manner that the drawers of the dispensing cabinet may be manually operated in the event of a power failure or problem with the cabinet. Those, and other advantages and benefits, will be apparent from the Description of the Preferred Embodiments herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be easily understood and readily practiced, the present invention will now be described, for purposes of illustration and not limitation, in conjunction with the following figures, wherein:
FIG. 1 is a diagram illustrating the relationship between a centralized storage location and a plurality of decentralized storage locations;
FIG. 2 is a diagram illustrating a process for distributing items and restocking of items based, at least in part, on records created during distribution;
FIG. 3 is one example of hardware located at a decentralized location implementing a closed system for performing dispensing operations;
FIG. 4 is one example of hardware located at a decentralized location implementing an open system for performing dispensing operations;
FIG. 5 is a diagram illustrating the flow of information between the computers used at various locations within a dispensing/restocking system.
FIG. 6 illustrates a unit dose drawer that may be used in the cabinet or the auxiliary cabinet of FIG. 3;
FIG. 7 is an exploded view of one example of the construction of an individual drawer of the type shown in FIG. 6;
FIG. 8 illustrates the unit dose drawer in a fully closed position in a cabinet without any other drawers;
FIG. 9 illustrates the unit dose drawer in a fully opened condition in a cabinet without any other drawers;
FIG. 10 is a flow chart illustrating a dispense operation from a unit dose drawer;
FIG. 11 is a perspective view of a drive chassis located at the rear of a unit dose drawer having twelve drawers;
FIG. 12 is a cross-section view taken along the lines XI—XI in FIG. 11;
FIGS. 13 and 14 illustrate details of portions of FIG. 12;
FIG. 15 illustrates the details of the worm drive;
FIGS. 16-20 are electrical schematics of a circuit for receiving drawer identification and distance information as well as certain feedback signals which are used by the circuit to generate certain control signals;
FIG. 21 is an electrical schematic of motor sensor interface electronics;
FIGS. 22 and 23 are electrical schematics for home sensor electronics;
FIG. 24 is an electrical schematic of logic for producing a “Master open/close SNS” signal;
FIG. 25 is an electrical schematic of a manual override circuit;
FIG. 26 is an electrical schematic of a speed control circuit;
FIG. 27 is an electrical schematic of current control circuit and a motor control interface; and
FIGS. 28 and 29 are electrical schematics of a drive select circuit and a plurality of relays used to drive a selected motor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagram illustrating the relationship between a centralized storage location 10 and various inventory destinations, including a plurality of decentralized storage locations 12 - 1 , 12 - 2 through 12 -n, patients 13 , and a remote facility 14 . Each of the decentralized storage locations 12 - 1 through 12 -n is capable of dispensing items stored at the location. The items may include medications, controlled medical supplies, medical supplies or items of a nature consistent with the facility in which the system illustrated in FIG. 1 is located. Items may be dispensed directly from centralized storage location 10 to patients 13 , or from the centralized storage location 10 to a remote facility 14 . Data typically flows from the decentralized storage locations 12 - 1 through 12 -n to the centralized storage location 10 . In response to that data, items are typically moved from the central storage location 10 to the decentralized storage locations 12 - 1 through 12 -n or to the remote facility 14 to restock such locations to either replenish dispensed items or to stock new items. Decentralized locations could include satellite pharmacies, computerized medication cabinets, stationary/mobile medication carts, nurse servers, remote hospital pharmacies, supply closets, supply cabinets, etc. Supplies can be reordered from distributors based on levels of stock in the centralized storage location 10 .
FIG. 2 illustrates a process which may begin with a step of dispensing an item at step of 16 from one of the decentralized storage locations 12 - 1 to a patient. A dispensing operation may occur in a variety of ways. In a medical facility, dispenses may be completed from medication orders or they may be completed from inventory lists, to name a few types of dispensing operations. Assuming a medication has been dispensed from decentralized storage location 12 - 1 , the medication may either be administered to a patient or returned as shown by step 18 . Medications may be returned for a variety of reasons such as the patient has checked out, been moved, or the patient's medication may have been changed. Medications may be returned to the decentralized storage location 12 - 1 . Certain types of medications may simply be replaced in the decentralized storage location 12 - 1 so as to be used in another dispensing operation, or may need to be disposed of.
The administration of medications occurring at step 18 may be carried out through the use of a hand-held device such as an AcuScan-Rx™ device available from McKesson Automation, Inc., 700 Waterfront Drive, Pittsburgh, Pa. Such devices are wireless devices which communicate with a database to verify the administration of medications to patients. Such communications enable the maintenance of a database of inventory levels as shown by step 20 . The database and associated computer system for maintaining the database of inventory levels may be located at the centralized storage location 10 or may be located remote therefrom. In either event, the computer system necessary for maintaining the database provides information which enables the centralized storage location 10 to perform step 22 of generating a restocking package. The generation of the restocking package may be done completely automatically, manually, or through some combination of manual and automatic processes. The restocking package is used to restock the decentralized storage location 12 - 1 .
Restocking packages may also be generated at centralized location 10 and delivered to the remote facility 14 . From facility 14 an item may be transferred as shown by step 24 . The transfer may be a dispensing step for a patient or a transfer to another location. Items may also be dispensed directly to the patient from the centralized location 10 .
FIG. 3 illustrates one example of hardware which may be located at any of the decentralized locations 12 - 1 through 12 -n. The hardware illustrated in FIG. 3 is comprised of an AcuDose-Rx™ cabinet 26 , having a control computer 32 , and an AcuDose-Rx™ auxiliary cabinet 28 , available from McKesson Automation, Inc. A supply tower 30 is also illustrated. The control computer 32 controls the operation of the cabinet 26 , auxiliary cabinet 28 , and supply tower 30 . The control computer 32 is also in communication with the central database.
To perform a dispensing operation a user logs onto the control computer 32 . After log-on, patient information and information regarding items to be dispensed is entered. Based on the entered information, various drawers 31 in the cabinet 26 and the auxiliary cabinet 28 , and various doors 33 on the supply tower 30 are unlocked. After the item to be dispensed has been removed, its removal is recorded at the control computer 32 . The user may continue to dispense items for the identified patient, or patient information for another patient may be entered. Entry of information, including log-in, can be performed in a variety of ways with a variety of input devices, e.g., through entry with a keypad, barcode scanning, touch screen, selecting items from a pick list, RF ID, flash memory, magnetic strips, OCR, etc. The reader will understand that the hardware illustrated in FIG. 3 is exemplary and is illustrated for purposes of demonstrating one type of hardware which may be located at the decentralized storage locations 12 - 1 through 12 -n.
The hardware illustrated in FIG. 3 limits access to the items to be dispensed to those individuals who have properly logged on. Thus, the hardware illustrated in FIG. 3 is referred to as a closed system for performing dispensing operations because a dispensing operation cannot be performed unless the user is identified to, and recognized by, the control computer 32 .
FIG. 4 illustrates another example of hardware which may be located at any of the decentralized storage locations 12 - 1 through 12 -n. The hardware is comprised of a first shelving unit 34 and a second shelving unit 36 . An optional interface computer 38 may be provided, which is in communication with the database. If the interface computer is 38 is not provided, a handheld device 40 can be carried into the area to perform the inventory of the shelves. The handheld device 40 is taken back to the centralized storage location 10 where the information is downloaded in any appropriate manner. Alternatively, the hand-held device 40 could be a wireless device communicating over a wireless network link. Alternatively, and as shown in FIG. 4, the hand-held device 40 may be located in the area and have a docking cradle 41 in communication with the interface computer 38 .
Each of the shelving units 34 , 36 is comprised of a plurality of bins 42 . Each of the bins carries indicia 44 which may be, for example, a barcode and/or a label identifying the contents of the bin. Additionally, items in the bins may have a bar code, label or other indicia directly on them or on their packaging. The bar code could be scanned, or other methods of inputting the data consistent with the type of indicia used, or push buttons or the like actuated, to perform a dispensing or other type of operation. In addition, the handheld device 40 could be used to generate an ad hoc order through its screen entry in the event that an item is not available to be scanned or otherwise have data pertinent thereto input. The number of shelving units 34 , 36 and the configuration of the bins 42 , depends upon the number and size of the items to be stocked. Because access to the bins 42 is not restricted, the hardware illustrated in FIG. 4 is referred to as an open system for performing dispensing operations. The reader will understand that the hardware illustrated in FIG. 4 is exemplary and is illustrated for purposes of demonstrating one type of hardware which may be located at the decentralized storage locations 12 - 1 through 12 -n.
FIG. 5 illustrates the computers used at various locations within a dispensing/restocking system of the type disclosed herein. As seen in FIG. 5, decentralized storage location 12 - 1 is where control computer 32 (if supplied) is located. Decentralized storage location 12 -n is where interface computer 38 (if supplied) is located. A carousel work station 46 is located at the centralized storage location 10 . The centralized storage location 10 may also have a Robot-Rx™ support station 48 which is used to control a robot.
A computer 50 , which may be located at centralized storage location 10 or may be located elsewhere, maintains the database for the system. The computer 50 receives information from the decentralized storage locations 12 - 1 through 12 -n and provides information to the carousel work station 46 and/or the Robot-Rx™ support station 48 to enable restocking packages 52 to be prepared. Additionally, dispenses to patients, distributions to satellite facilities, and the like may occur from centralized location 10 . An interface PC 54 may be provided to enable external systems, such as a PC 56 on which a hospital information system resides, to communicate with the computer 50 on which the database is located. Completing the description of FIG. 5, as has been previously described, restocking packages 52 are prepared at the centralized storage location 10 and delivered to the decentralized storage locations 12 - 1 through 12 -n.
Returning to FIG. 3, the cabinet 26 available from McKesson Automation, Inc. may be configured with eight (8) drawers and has a maximum capacity of 384 line items. The control computer 32 operates in conjunction with a color touch screen monitor 90 and a full sized keyboard 92 . An integral uninterrupted power supply (not shown) is provided. A scanner port may also be provided to attach a bar code scanner.
The auxiliary cabinet 28 available from McKesson Automation, Inc. attaches to the main cabinet 26 to expand storage space of narcotic, floor stock and PRN medications. Like the cabinet 26 , the cabinet 28 may be configured with eight (8) drawers and has a maximum capacity of 384 line items.
A unit dose dispensing drawer 58 is illustrated in FIG. 6 . As the name implies, the unit dose dispensing drawer 58 provides single unit-of-use access to high security medications that are to be stored within either the cabinet 26 or auxiliary cabinet 28 , although access to more than a single unit could be provided if the user so desired. The unit dose dispensing drawer 58 uses one standard drawer space within the cabinets 26 , 28 . The unit dose dispensing drawer 58 may be provided with twelve (12) individual drawers 60 - 1 through 60 - 12 or in a wider six-drawer version (not shown). Each of the individual drawers 60 - 1 through 60 - 12 is motor-driven so as to provide access to exactly the number of units requested. The construction of the individual drawers 60 - 1 through 60 - 12 is shown in FIG. 7 .
Each of the drawers 60 - 1 through 60 - 12 is comprised, in the presently preferred embodiment, of a drivable tray 62 which moves relative to a slide 61 , an insert 63 and a lid 64 . The drivable tray 62 is connected to a chain, described herein below, so as to be driven between an open position shown in FIG. 7 and a closed position.
The insert 63 has a tab 65 which mates with a slot 66 in the tray 62 . The insert is approximately the size of the tray 62 such that the insert 62 defines the volume of the drawer 60 - 1 . A pin 67 and spring 68 are inserted through an opening in the side of the tray 62 and retained within insert 63 by a pushbutton 69 . Upon depressing the pushbutton 69 , the spring 68 pushes pin 67 out of its locked position thereby enabling the insert 63 to be removed from the tray 62 . The pin 67 , spring 68 , and pushbutton 69 form a release mechanism. The insert 63 can only be removed from the tray 62 if the tray 62 is driven to its fullest extent. Access to the command to drive the tray 62 to its fullest extent can be password protected so that only administrators and/or pharmacy techs have access.
The unit dose dispensing drawer of the present invention will also support a feature called “auto ID.” This feature incorporates a chip, switch, or other mechanism for generating, for example, an eight bit signal. The control computer's 32 software automatically detects the eight bit signal and determines from a table the hardware configuration of any drawer type that is installed in the cabinet. Eight bits enables 256 possible drawer types and configurations using this feature. This feature could also be used on standard drawers used in the cabinets. Additionally, the drawers can be bar-coded to provide data about the drawers.
The lid 64 is comprised of a plurality of individual lids 70 which are designed to cover individual compartments 71 . The lid 64 is held in place with respect to the insert 63 by a rod 72 . As seen in FIG. 7, the hinge between each individual lid 70 and each individual compartment 71 is along the side of the insert 63 . Accordingly, the individual lid 70 can be fully opened only when the tray 62 is driven so that the individual lid 70 is completely clear of the front portion of the cabinet. The lid 64 can be locked, or can be provided with a tamper-resistant seal, to prevent access when the insert 63 is removed from the tray 62 . That capability can be used to centrally restock the cabinet as inserts 63 are swapped and refilled in the pharmacy or other central storage location. Thus the inserts 63 may provide the function of the restocking packages 52 of FIG. 5 .
The drawer 60 - 1 is completed by a fascia piece 74 and a knob 75 . The end of the tray 62 may have slots and/or tabs which mate with slots and/or tabs at the corresponding end of insert 63 .
Those of ordinary skill in the art will recognize that other types of inserts 63 , other configurations for providing locked lids, other configurations for releasing the insert from the tray, and other fascia and knob configurations are possible. FIG. 7 is provided only for the purpose of illustrating a presently preferred embodiment. Those of ordinary skill in the art will recognize that many modifications and variations are possible.
FIG. 8 illustrates the unit dose drawer 58 of FIG. 6 in a fully closed position in a cabinet 78 without any other drawers. FIG. 9 illustrates the unit dose drawer 58 of FIG. 6 in a fully opened position in the cabinet 78 .
FIG. 10 is a flow chart illustrating a dispense operation from a unit dose drawer. Assuming that the nurse has properly logged into the cabinet and identified a patient, the dispense operation from the unit dose drawer begins at step 80 in which the nurse indicates the number of units of a medication, previously identified, to be dispensed. At step 82 , the control computer 32 identifies the drawer containing the desired medication and the amount of travel necessary to make the next pocket or pockets containing the medication accessible. At step 84 , signals are sent to a circuit which causes the identified drawer to travel the necessary distance thereby providing access to the necessary pocket or pockets. The nurse then removes the medication from the accessed pockets and provides an indication that the items have been dispensed at step 86 . The control computer 32 , upon receiving an indication that a dispense has occurred, at step 88 sends signals which identify the open drawer and cause the drawer to be driven to its closed position. The foregoing process may be used for one unit-dose of medication where the same medication is in all pockets or can be used for multiple units of the same medication where the same medication is in all pockets. In a situation where multiple units of the same medication are to be dispensed, but different medications are in the drawer pockets, the nurse indicates the number of units to dispense. The drawer then fully extends exposing all of the pockets. The nurse dispenses the desired medications from the fully opened drawer. Such a “matrix mode” of dispensing would be used only in connection with non-controlled substances.
The mechanical hardware for driving the trays 62 is illustrated in FIGS. 11 through 15. In FIG. 11, a perspective view of a drive chassis 100 is illustrated. The chassis carries motors 102 - 1 through 102 - 12 which are each used to drive one tray 62 . As seen best in FIG. 15, a shaft 104 - 1 through 104 - 12 of each motor drives an associated worm gear 106 - 1 through 106 - 12 , respectively. As seen best in FIGS. 12 and 15, each side-by-side pair of motors drives one of the upper trays and the lower tray directly beneath it. That is accomplished, in part, by each worm gear 106 - 1 through 106 - 12 mating with and driving a gear 108 - 1 through 108 - 12 . An upper shaft carries odd numbered gears 108 - 1 , 108 - 3 , 108 - 5 , 108 - 7 , 108 - 9 , and 108 - 11 while a lower shaft carries even numbered gears 108 - 2 , 108 - 4 , 108 - 6 , 108 - 8 , 108 - 10 , and 108 - 12 . An upper clutch rod 110 and a lower clutch rod 111 are responsive to an override mechanism 113 operated by a user through an override bar 115 . Movement of the override bar 115 to the right in FIG. 11 causes both the upper clutch rod 110 and lower clutch rod 111 to move to the left as seen in FIG. 11 . As will now be described, lateral displacement of the upper clutch rod 110 and lower clutch rod 111 disengages the trays from the motors.
Each of the gears 108 - 1 through 108 - 12 has associated therewith a moveable gear 117 - 1 through 117 - 12 , respectively, seen best in FIGS. 13, 14 , and 15 The moveable gears 117 - 1 through 117 - 12 are free to move along their respective shafts while at all times being drivable by their associated gear 108 - 1 through 108 - 12 , respectively. That may be accomplished, as seen in FIGS. 13 and 14, by providing gears 108 - 1 through 108 - 12 with a hub 120 - 1 through 120 - 12 having a flattened or shaped exterior circumference which mates with a similarly shaped interior circumference of the moveable gears 117 - 1 through 117 - 12 , respectively.
Each of the moveable gears 117 - 1 through 117 - 12 has associated therewith a clutch fork 119 - 1 through 119 - 12 , respectively, best seen in FIG. 15 . Each of the clutch forks 119 - 1 through 119 - 12 is connected to one of the clutch rods 110 , 111 . As seen in FIGS. 13 and 14, teeth 122 - 1 through 122 - 12 of moveable gears 117 - 1 through 117 - 12 are adapted to engage teeth 124 - 1 through 124 - 12 of a driven gear 126 - 1 through 126 - 12 , respectively. Each of the driven gears 126 - 1 through 126 - 12 has a set of teeth 128 - 1 through 128 - 12 , respectively, along its outer periphery.
During normal operation, the clutch rods 110 , 111 are biased so that the teeth 122 - 1 through 122 - 12 of moveable gears 117 - 1 through 117 - 12 mate with the teeth 124 - 1 through 124 - 12 of driven gear 126 - 1 through 126 - 12 , respectively. When the override bar 115 is moved to the right in FIG. 11, the clutch rods 110 and 111 overcome the bias, normally provided by springs, and therefore move to the left as seen in FIG. 11 . Movement to the left of the clutch rods 110 , 111 causes each of the clutch forks 119 - 1 through 119 - 12 to move to the left pushing with it the moveable gears 117 - 1 through 117 - 12 , respectively. Movement of the moveable gears 117 - 1 through 117 - 12 to the left, causes the teeth 122 - 1 through 122 - 12 of the moveable gears 117 - 1 through 117 - 12 to disengage from the teeth 124 - 1 through 124 - 12 of driven gear 126 - 1 through 126 - 12 , respectively. When that occurs, driven gears 126 - 1 through 126 - 12 are no longer connected via the worm drive to the electric motors 102 - 1 through 102 - 12 .
A chain 130 - 1 through 130 - 12 engages the teeth 128 - 1 through 128 - 12 of driven gear 126 - 1 through 126 - 12 , respectively. The other end of the chain may engage an idler gear, one of which 131 - 3 is shown in FIG. 11 . Each chain is connected to one of the trays so that the tray moves with the chain. In FIG. 11, chain 130 - 3 is connected to tray 62 - 3 . During normal operation, when any of the motors 102 - 1 through 102 - 12 is energized, its shaft rotates thereby rotating the worm gear 106 - 1 through 106 - 12 and associated gears 108 - 1 through 108 - 12 , which in turn rotates its associated moveable gear 117 - 1 through 117 - 12 , which drives the driven gear 126 - 1 through 126 - 12 causing the chain 130 - 1 through 130 - 12 to move, respectively. Because each tray is attached to its own chain, the position of the tray can be controlled by controlling the amount of rotation of each motor's shaft
The worm gear is designed to be self locking. More specifically, when the motor is not energized, the worm gear is designed so that there is sufficient friction to prevent the tray from moving, and hence preventing the drawer from being opened or closed. In the event of a power failure, control computer 32 malfunction, or other event which creates a state in which the drawers cannot be driven by the motors to their open position, the override bar may be used as previously described to disengage the moveable gears from the driven gears. When that occurs, the drawers are no longer connected to the worm gear such that the driven gears 126 - 1 through 126 - 12 are free to rotate thereby allowing each of the drawers to be opened and closed.
Returning to FIG. 11, each of the motor shafts 104 - 1 through 104 - 12 carries a sensor blade 132 - 1 through 132 - 12 , respectively. The sensor blades 132 - 1 through 132 - 12 each carry two magnets 133 - 1 through 133 - 12 and 134 - 1 through 134 - 12 , respectively. Each of the motors 102 - 1 through 102 - 12 is provided with a Hall effect sensor 136 - 1 through 136 - 12 , respectively. Thus, as the sensor blade 132 - 1 through 132 - 12 rotates its magnets 133 - 1 through 133 - 12 , 134 - 1 through 134 - 12 , the magnets are brought adjacent to the Hall effect sensor 136 - 1 through 136 - 12 , respectively, such that a 360° rotation of the motor shaft produces two pulses. Those pulses are input to control electronics which will now be described in conjunction with FIGS. 16 through 29.
Turning first to FIGS. 16, 17 and 18 , two eight bit words are received in FIG. 16 from the control computer 32 . The first eight bit word 150 represents the distance a drawer is to travel. From the second eight bit word, four bits 152 represent a drawer select signal, a bit 154 is representative of a start transaction, a bit 155 is representative of direction, a bit 156 is representative of a “clear error” signal, and a bit 157 is representative of a “retry” signal. The distance bits 150 are input to a counter 158 (FIG. 18 A). A comparator 160 (FIG. 18C) is responsive to the counter 158 . The comparator 160 is also responsive to a plurality of switches 162 which set a value to which the comparator compares the output of the counter 158 .
The counter 158 is loaded with the distance information encoded in the bits 150 . The counter 158 then begins counting down from the loaded value. While the counter is counting down, the drawer is being driven at a first, high speed. When the counter reaches the value set by the switches 162 , the comparator 160 produces a signal available at node 164 which is referred to as the “low speed enable” signal. This indicates to a circuit, to be described later, that the drawer has traveled a substantial portion of the distance that it is to travel and the speed should now be reduced for the remainder of the distance to be traveled.
The drawer select bits 152 are latched in a latch 166 seen in FIG. 16 . The drawer select bits 152 are input, via FIG. 18, to a drive select/control circuit described herein below. The drawer select bits 152 are also input, via FIG. 18, to motor sensor select/clock circuit 168 , see FIG. 17, which is used to identify which drawer is to be actuated for purposes of selecting appropriate feedback signals from the actuated drawer.
FIG. 19A has in the upper portion thereof a motor enable path 170 which is responsive to a “count complete/enable” signal from FIG. 18A as well as a “delayed start transaction/retry” signal from FIG. 18 C. Those two signals are processed as shown in motor enable path 170 to produce a “master motor enable” signal.
In the middle of FIG. 19A, a flip-flop 172 is provided which is responsive to the motor enable path 170 as well as the “delayed start transaction/retry” signal available from FIG. 18 C. The flip-flop 172 produces the signals “hardware busy” and “command lock out”.
Finally, in FIG. 19B, a circuit path 174 is provided for producing an “error” signal in response to an “overload detect” signal (indicative of an overcurrent condition) input to the circuit path 174 . In response to the detection of an overcurrent condition, the “error” signal is generated.
FIG. 20 illustrates a circuit path 176 for producing a “master low speed enable” signal through the logical combination of the “low speed enable signal” produced by the comparator 160 of FIG. 18 and a “drawer open/closed feedback” signal from FIG. 17 .
FIG. 21 illustrates motor sensor interface electronics 178 . The motor sensor interface electronics 178 receive the signals produced by the Hall transducers to produce signals MD_ 1 through MD_ 12 MTR SNS signals which are input to the motor sense select/clock circuit 168 shown in FIG. 17 . In FIG. 21, the motor sensor interface electronics are shown for four of the drawers.
FIG. 22 illustrates home sensor electronics 180 for the upper individual drawers. Each of the trays is provided with an upstanding metal tab or flag ( 95 in FIG. 7 ). The drive chassis carries sensors, each sensor comprised of one LED 182 - 1 , 182 - 3 , 182 - 5 , 182 - 7 , 182 - 9 , and 182 - 11 and one corresponding light sensitive transistor 184 - 1 , 184 - 3 , 184 - 5 , 184 - 7 , 184 - 9 , and 184 - 11 corresponding to the upper trays 62 - 1 , 62 - 3 , 62 - 5 , 62 - 7 , 62 - 9 , and 62 - 11 , respectively, of which only tray 62 - 3 is shown in FIG. 11 . When each tray 62 - 1 , 62 - 3 , 62 - 5 , 62 - 7 , 62 - 9 , and 62 - 11 is in its closed or home position, the flag carried by that tray blocks the light produced by the LED 182 - 1 , 182 - 3 , 182 - 5 , 182 - 7 , 182 - 9 , and 182 - 11 from being received by the corresponding light sensitive transistor 184 - 1 , 184 - 3 , 184 - 5 , 184 - 7 , 184 - 9 , and 184 - 11 , respectively. The signals produced by the sensors 184 - 1 through 184 - 12 are input to the logic shown in FIG. 23 to produce MD_ 1 through MD_ 12 O/C (open/closed) signals and MD_ 1 through MD_ 12 Master O/C signals.
The MD_ 1 through MD_ 12 O/C signals are input to the logic circuit 188 illustrated in FIG. 24 . The logic circuit 188 combines the signals to produce a “Master open/close SNS” signal. The MD_ 1 through MD_ 12 Master O/C signals are input to the motor sensor select/clock circuit 168 illustrated in FIG. 17 .
FIG. 25 illustrates a manual override circuit 190 . The manual override circuit 190 is responsive to the position of the override bar 115 to produce a signal indicative of a manual override. When a manual override is in effect, a “Manual Override” signal is produced by the manual override circuit 190 illustrated in FIG. 25 .
FIG. 26 illustrates a pulse width modulated speed control circuit 192 responsive to the MTR-SNS signal produced by the motor sense select/clock circuit 168 of FIG. 17 . The speed control circuit produces a “speed enable” signal.
FIG. 27 illustrates in the lower portion a motor control interface 194 producing signals input to relays 196 - 1 through 196 - 12 illustrated in FIG. 28 . FIG. 27 also illustrates a current control circuit 198 . The current control circuit 198 is responsive to an overcurrent condition, e.g., the drawer has run into an obstacle, jammed, or is otherwise having trouble moving, and produces a “current enable” signal. The current enable signal is used to drive the motors up to a maximum overcurrent condition. The current control circuit 198 may be viewed as a force control. More specifically, sufficient force is generated to overcome system friction and mass, but not enough force to injure anyone should they be in the path of a moving drawer. The control computer 32 may be provided with software for providing an automatic retry and an anti-pitch movement whenever a jam is detected. The relays 196 - 1 through 196 - 12 of FIG. 28 are responsive to signals produced by the logic circuit 200 illustrated in FIG. 29 .
While the present invention has been described in connection with preferred embodiments thereof, those of ordinary skill in the art will recognize that many modifications and variations are possible. The present invention is intended to be limited only by the following claims and not by the foregoing description which is intended to set forth the presently preferred embodiment. | A drawer for use in a dispensing cabinet is comprised of a tray movable between an open position and a closed position. An insert, approximately the length of the tray, is carried by the tray and defines the volume of the drawer. A lockable or sealable lid is carried by the insert. A release mechanism is provided to connect the insert to the tray in a manner that allows the insert to be easily disconnected from the tray. Removal of the insert enables inserts to be swapped so that inserts from which inventory has been depleted can be replaced with stocked inserts. A dispensing cabinet and a method of restocking the cabinet are also disclosed. | 6 |
BACKGROUND OF INVENTION
The invention relates generally to an adjustable seat back belt positioning juvenile booster car seat that folds compactly for easy transportation, thereby reducing shipping costs as well as physical space requirements at the retail level.
Passenger restraint systems in automobiles are generally well suited to properly restrain adults but not well suited to properly restrain children. Accordingly, vehicle restraint systems must be supplemented by devices such as booster seats, which may be broadly defined as a seat that relies primarily on the vehicle's lap and shoulder belts to retain the seat in the vehicle and to restrain the child's torso. These seats include a seat portion to elevate the child above the vehicle's seating surface to a position in which the vehicle's shoulder belt is better positioned on the child and which properly positions the vehicle lap belt on the child's torso, and may also include a back portion. A common construction technique for booster seats with backs is to mold the seat and back portions from rigid plastic and cover them with a cushion or pad.
Known booster seat designs suffer from several drawbacks. First, the large L-shaped bodies tend to be relatively expensive and difficult to mold in one piece, especially if the seat includes wings and a lap belt path. Additionally, these booster seat designs suffer from a large size which is difficult to ship, store, package for manufacturers, and difficult to store and transport for consumers.
The manufacturing expense associated with a rigid molded body derives from the complex molding process required. One solution is to mold the seat as a plurality of separate, less complex, pieces and assemble the separate pieces into a rigid whole. Unfortunately, molding the seat as separate pieces requires additional tooling to mold the separate pieces and adds assembly steps, both of which add to the cost of manufacture. Thus, the savings due to less complex molding is offset by increased manufacturing and assembly costs and the seat is still large and bulky.
Therefore, what has been lacking in the industry is an easy to manufacture L-shaped car seat which is easily collapsed or foldable from an L-shaped position to a more compact position for ease of transportation and storage, yet which can be similarly, easily unfolded to its L-shaped use position.
Additionally, what has been lacking is the ability to further elongate or contract a car seat back to more accurately match the height of an occupant's head and shoulder with appropriately molded head restraint components of the seat back and shoulder belt path while maintaining a complete back support. Typically, the industry adopts a one-size-fits-all approach, which does not maximize the safety of the occupant by adjusting the seat size to fit the occupant. Those which adjust the headrest do not adjust the back, thus leaving an open area with no support. This disadvantage is eliminated by using the design of the present invention.
SUMMARY OF INVENTION
The general configuration for a belt-positioning booster car seat (generally intended for use with children weighing 30 to 80 or 100 pounds) is typically a molded plastic seat with a back and a seating surface. These surfaces have adjacent side walls that help contain and protect the child occupant. Slots or recesses on both sides of the seat in the occupants “hip area receive the lap belt portion of an auto belt restraint. Hooks or slots on both sides of the seat on the head/shoulder area receive the shoulder belt portion of the auto restraint in multiple height positions. The booster seat positions the auto belts to properly restrain the small occupant. The shoulder belt is especially important and the clips or slots on the shoulder area of the booster, when used properly, guide the belt across the occupants” shoulder and not on the head or neck. The lap belt is equally important and the slots in the hip area guide the lap belt across the bony pelvis, not the soft abdomen area.
Properly using a car seat is always an issue as seats that adapt to a wide range of occupants introduces the potential for misuse and inherent increased risk to children through that misuse. It has always been a goal of car seat designers to make fits to children better and adjustments easier and less confusing.
Typical bulkiness of a child's car seat is an issue that affects many levels. Transporting a large one-piece seat (when it is not being used as a restraint) is cumbersome and inconvenient for the consumer. Shipping and packaging a large seat is costly for the manufacturer, especially if shipping overseas and retail shelf space is always at a premium. If the booster seat could be folded, the drawbacks of a bulky one-piece seat could be reduced.
In one aspect of this invention, an effective means of securing a growing child from 30 to 80 or 100 pounds is provided while providing optimum occupant comfort. The resulting invention attempts to address the fit issue of a wide weight range of children and the ease and convenience of how that fit is achieved. The folding element of the invention allows easier consumer transport, less expensive freight and packaging costs, and reduced retail shelf space requirements.
This folding booster is comprised of a folding child's belt positioning booster car seat with adjustable height back. Additional features include an armrest and cup holder, both on each side of the seat. This folding booster is comprised of two main molded folding components, a seat and an adjustable height positioning back assembly. They are joined at a main pivot directly behind and slightly above the lap belt recesses. This pivot allows the back and seat sections to fold toward each other, permitting the seat to be transported more easily than a non-folding seat because of the smaller size. This reduction in size requires a package roughly half the size of a typical non-folding seat, which is very beneficial for packaging and freight cost savings as well as minimizing retail shelf space at the consumer store location.
The fixed part of the back assembly is coupled to the seat component of the restraint just above the seating surface and directly behind the lap belt recesses. The fixed back and seat are coupled such that they share a common axis that allows the fixed back and seat to pivot and fold toward each other. The seat and back assembly are each shaped such that they share a common axis that allows the fixed back and seat to pivot and fold toward each other. The seat and back assembly are each shaped such that they nest when folded together, allowing a compact fold.
The fixed back is constructed with all areas parallel to a central axis or spine of the back. The adjustable back is attached over the top or in front of the fixed back. The inner contour of the adjustable back mates with the outer contour of the fixed back that is parallel to the central axis or spine. The inner contour of the movable back is also parallel to the central axis or spine as it nests with the outer contour of the fixed back. The outer contour of the movable back need not be parallel to the central axis.
The surfaces that comprise the fixed back outer contour consist of a generally flat back surface and winged or forward protruding surfaces that extend the length of the back surface and offer side support to the seat occupant. The form of the fixed back may take any shape that permits a telescoping motion with the adjustable back. The movable back is attached to the fixed back so it can slide or telescope along the fixed back in a defined range of motion. This range of motion is defined by the shoulder heights of the seat occupants as is required by a 30 to 80 or 100 pound child.
Approximately one-third of the way down the movable back from the top are two generally horizontal and symmetrical slots that intersect the back surface from the sides. These slots allow the auto shoulder belt to penetrate the seat back and be positioned directly above the occupant's shoulder. Each slot has a hook that aids in retaining the auto belt within the slot. The defined range of motion of the movable back permits the proper positioning of these slots to fit the shoulder heights of the children within the seat's occupant weight range. The entire movable back moves as is required to properly position the shoulder belt slots for the occupant. A means for incrementally adjusting and maintaining the height of the movable back is locate behind the movable back.
Directly above the shoulder belt slots is a contoured headrest area with wings or surfaces that extend generally forward, away from the back seating surface and provide head protection and support. The entire inner surface of the headrest area is lined with energy absorbing foam, e.g., expanded polystyrene. Because the headrest area is integral to the movable back, when the shoulder belt slots are properly positioned for the occupant, the headrest is automatically positioned and the contiguity of the surface is maintained.
Armrests are located on both sides of the seat, attached to the main seat fold pivot. The armrests can be positioned up or down via a pivoting attachment and share the same pivot axis as the main seat fold. In an optional embodiment, the armrests also serve as locks to control the seat fold. In this locking embodiment, the mechanism inside each armrest hub consists of a plunger than can engage both the seat and the fixed back preventing their rotation about the main pivot. Rotating an armrest up, cams the plunger out of mutual engagement with the seat and fixed back and no longer prevents rotation. Both armrests must be in the same up or down position to allow or prevent rotation.
A latch behind the fixed back near the main seat pivot area prevents the seat from folding inadvertently. This spring biased latch must be released from engagement with the rear of the seat component before the fold can be initiated. The arm rests must be in their up (unlocked) position as well prior to the seat being folded in the optional locking armrest embodiment.
When the seat is folded, i.e., the back generally parallel to the seat, the armrests can both be rotated to their down or locked position, which will mutually engage the seat and fixed back in this position and prevent rotation. The shape of the seat and fixed back in the main pivot area allow the folded seat to stand upright like a suitcase for convenience. To unfold the seat, both armrests must be folded up to the unlocked position to allow the seat and the fixed back to rotate freely.
The order in which the pivoting components are actuated in the optional locking armrest embodiment, ensures that whoever is folding the seat is not accidentally pinched by the scissor action of the seat back and armrests as they would approach each other if the fold were initiated when the armrests were in the down position.
Under the seating surface on both sides of the seat are cup holders that extend outward individually and provide areas for beverage or snack storage. Molded detents maintain the stored or extended positions of the cup holders. The cup holders are retained by a molded plate that has a smooth surface on the bottom that helps protect auto upholstery.
In one aspect of the present invention, the foldability of the car seat permits ease of transportation, economical packaging, shipping and low retail shelf space requirements and consumer benefits from the standpoint of ease of transporting the car seat from location to location.
In another aspect of the invention, parallel walls on the seating surfaces allow adjustment of the whole seat back to fit children of varying physical characteristics, and not through only adjustment of the headrest.
These and other objects of the present Invention will become more readily apparent from a reading of the following detailed description taken in conjunction with the accompanying drawings wherein like reference numerals indicate similar parts, and with further reference to the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein: FIG. 1 is a front perspective view of a foldable car seat with extendable seat back showing the movable portion of the seat back in a fully collapsed position; FIG. 2 is a front perspective view of FIG. 1 illustrating the movable portion of the seat back in an expanded position; FIG. 3 is an exploded view of FIG. 1 ; FIG. 4 is a perspective view of FIG. 1 illustrating the positioning of the vehicle seat belts with the car seat; FIG. 5 is a rear perspective view of the foldable car seat of FIG. 1 ; FIG. 6 is right perspective view of an armrest interfacing with a cam surface upon rotational movement therewith illustrating the seat back side and armrest in their upright position; FIG. 7 is a left perspective view of FIG. 6 ; FIG. 8 is a right perspective view similar to FIG. 6 illustrating the seat back side and armrest in a horizontal position; FIG. 9 is a left perspective view of FIG. 8 ; FIG. 10 is a right perspective view similar to FIG. 6 illustrating the seat back side in an upright position and the armrest in a horizontal position; FIG. 11 is a left perspective view of FIG. 10 ; FIG. 12 is a side elevational view of an alternative embodiment illustrating two low-level detents in the hub; FIG. 13 is an exploded view shown in partial cross-section of the car seat latch; FIG. 14 is a side perspective view of a fixed back hub; FIG. 15 is a side elevational view of the car seat in a folded or collapsed position; and FIG. 16 is a rear perspective view of the adjustment mechanism of the movable component of the back assembly.
DETAILED DESCRIPTION
Referring now to the drawings wherein the showings are for purposes of illustrating the preferred embodiment of the invention only and not for purposes of limiting the same, the figures show a collapsible car seat with an adjustable back to better accommodate occupants of different heights and weights. In one optional embodiment of the invention, the car seat will pivot only through the selective positioning of the two handles, while in a second embodiment, this selective locking feature is not present.
As illustrated in FIG. 1 , car seat 10 has a fixed back member 14 , a positionable or movable back member 16 and a seat member 12 , the fixed back member pivotally connected to seat member 12 by a pair of pivot pins 48 and retaining washers 46 to which pivotable handles 38 a , 38 b are positioned on opposite sides. As better shown in FIGS. 2-3 , fixed back member 14 further comprises a seat back 62 , a pair of raised seat back sides 34 , a curvilinear top ledge 74 having a vertically extending locking member 78 having a plurality of vertically spaced apart indentations 80 disposed thereupon, and a seat back bottom edge 96 . Fixed back member 14 additionally has at least one, preferably a pair of vertically extending spaced apart slots 60 which facilitate sliding or telescoping movement, yet retain engagement with movable back member 16 by screws 126 and washers 127 . This movable member comprises a seat back 18 , a pair of raised seat back sides 36 , a top 28 and a bottom edge 58 . Disposed between top 28 and bottom 58 edges, are a pair of inwardly extending apertures 98 creating a neck region 100 with retaining means 30 for securing a vehicle shoulder belt therein. Between neck region 100 and top edge 28 , is positioned headrest area 72 having opposed raised sides 24 for positioning about a head of an occupant user of the car seat. In one embodiment, headrest area 72 will have a foam liner 20 for positioning thereupon and in mating engagement with headrest area 72 , raised lateral edges 102 for mating engagement with similarly geometried raised lateral edges 24 , top edge 104 for mating engagement with top edge 28 , and bottom edge 26 for overlap with neck region 100 . To facilitate transport of car seat 10 , is aperture 22 positioned within movable back member 16 toward top edge 28 .
Optimal adjustment of headrest area 72 in conjunction with foam liner 20 is effected by essentially vertical telescoping movement of movable back member 16 adjacent fixed back member 14 by inward compression of handles 32 of locking member shafts 66 which are normally outwardly biased through the interaction of springs 70 on shafts 68 in communication with spring stops on moving back 16 as illustrated in FIG. 16 . Inward compressive movement disengages rearward facing teeth or serrations or projections 64 from interlocking engagement with corresponding indentations or grooves 80 thereby permitting vertical height adjustment of movable back member 16 . Removal of the compressive force on locking member handles 32 results in re-locking engagement of teeth 64 with corresponding indentations 80 .
As better illustrated in FIG. 5 , the rear of fixed and movable seat back sides is generally hollow, optionally with a plurality of ribs 135 for structural integrity in the fixed back member 14 as well a plurality of ribs 140 , 142 in the movable back member 16 for additional structural integrity. Fastening means such as a washer 136 and a screw 134 maintain locking member handles 32 onto movable back member 16 yet permit compressive movement normal to the vertical axis of the back of the car seat within slot 138 . Locking engagement of the fixed and movable back of car seat 10 is effected by pivotal movement of outwardly spring biased 141 handle 140 of latch 84 about pivot pin 86 with latch projection 125 securing a lip 124 of car seat member 12 as best illustrated in FIG. 13 . Downward projections 76 function as legs for car seat 10 when in its collapsed or folded position. Collapsing of the car seat backs to the seat or seat to the backs, involves releasing latch 84 followed by clockwise rotational movement of seat member 12 toward fixed back member 14 and movable back member 16 . Phrased alternatively, and equivalently, the rotational movement may be thought of as counterclockwise if fixed back member 14 and movable member 16 are rotated toward seat member 12 . Uncollapsing or unfolding is automatic as latch 84 overrides lip 125 of car seat member 12 and snaps into place beyond lip 124 . Optionally, instruction pouch 82 is affixed to the rear of fixed back member 14 .
As illustrated in FIG. 4 , movable seat back side 16 has a shoulder belt guiding device 30 affixed to headrest area 72 and defines an apertured opening 98 for retention of the shoulder belt 142 regardless of where movable back 16 is positioned. Additionally, lap belt 144 is guided and positioned appropriately on a user's pelvic area by recessed areas 44 on either side of seat member 12 .
Seat member 12 further comprises a curvilinear seat bottom 50 , a pair of raised bottom sides 52 , each side generally being hollow and having a front side 54 and a rear side 106 . At the front of the base of seat member 12 is seat protection member 94 which has a generally rectangular base 108 with a pair of rearwardly extending leg members 110 . Seat member 12 optionally has a recessed portion 44 for positioning of a lap belt 144 correctly across the body of an occupant. In one embodiment, and optionally, a pair of retractable cup holders 56 are insertable into seat protection member 94 and secured by tracks 92 which interface with slots 90 within projections 88 , retained by washers 148 and screws 146 . While a horizontal engagement is illustrated in FIG. 3 , it should be noted that other arrangements are envisioned within the scope of this invention, e.g., pivoting cup holders. As better illustrated in FIG. 3 , rotational armrests 40 positioned on either side of the seat comprise an outer housing 38 a or 38 b, an inner plate 118 and an exterior cover 120 fixedly attached to the car seat by pivot pin 148 .
Bottom seat member 12 and fixed back member 14 are secured together by a pair of pins 48 securing back cylindrical housing 112 , seat cylindrical housing 42 and outer armrest 38 together encapsulating sliding latch 116 therein. As illustrated in FIGS. 6-7 , with armrest 38 in an upright an unlocked position, sliding latch extension 122 is in its elevated unlatched position 129 in back cylindrical housing 112 due to the movement of cam follower 124 in contact with cam surface 126 of armrest 38 a. Raising the armrest handle 38 a allows cam surface 126 to act on cam follower 124 on the sliding latch 116 compressing the spring 114 and allowing free rotation.
In FIGS. 8-9 , due to the spring 114 biasing sliding latch 116 in a downward direction, sliding latch 122 engaged with the folded latched position 130 of the seatback hub, the seat is in a latched folded position. Once again, as illustrated in FIGS. 10-11 , with the fixed seat back unfolded and armrest 38 a in a locked position due to the relationship of cam surface 126 with cam follower 124 , coupled with the spring biasing, sliding latch 116 is fixed into a non-rotating position on the seat back hub. Thus, it can be seen that only when the armrest 38 a is in the upright position, is rotational movement possible due to the interaction of the cam surface upon cam follower 124 moving sliding latch into unlatched position 129 on seatback hub 112 .
Alternatively, the ability to selectively rotate the armrest to effect collapsing of the carseat, a feature which minimizes the ability to pinch a finger upon performing the collapsing motions, need not be present as illustrated in FIG. 12 wherein cam follower 124 follows the cam surface 126 in the armrest and detents in either detent 150 or 152 on one side and operates in a similar manner in the armrest on the other side for the purpose only to allow the armrest an up or down detented position. As shown in FIG. 14 , the raised area on back cylindrical housing 112 is also reduced in height to where sliding latch extension 122 can override it thus detenting the back at position 154 and not locking it.
When car seat 10 is in its fully collapsed position, the seat back assembly and seating surface nest, thereby allowing a compact fold, as illustrated in FIG. 15 still leaving sufficient gap between armrest handle 40 or raised seat back sides 36 and raised bottom sides 52 to not pinch an individual who is collapsing the car seat.
In manufacture, the car seat 10 is typically made of plastic, preferably polyolefin, more preferably rubber modified polypropylene and covered with a fabric, typically including a foamed backing material for the occupant. A non-exhaustive list of possible plastics would include polyolefins, polycarbonates, polyesters, polyurethanes, polyalkylene terephthalates, polysulfones, polyimides, polyphenylene ethers, styrenic polymers, polycarbonates, acrylic polymers, polyamides, polyacetals, halide containing polymers and polyolefin homopolymers and copolymers. Additionally included would be mixtures of different polymers, such as polyphenylene ether/styrenic resin blends, polyvinylchloride/ABS or other impact modified polymers, such as methacrylonitrile containing ABS, and polyester/ABS or polyester plus some other impact modifier may also be used. Such polymers are available commercially or may be made by means well known in the art.
More specifically, polymers of monoolefins and diolefins, for example would include polypropylene, polyisobutylene, polybutene-1, polymethylpentene-1, polyisoprene or polybutadiene, as well as polymers of cycloolefins, for instance of cyclopentene or norbornene, polyethylene (which optionally can be crosslinked), for example high density polyethylene (HDPE), low density polyethylene (LDPE) and linear low density polyethylene (LLDPE) may be used. Mixtures of these polymers, for example mixtures of polypropylene with polyisobutylene, polypropylene with polyethylene (for example PP/HDPE), may also be used. Also useful are copolymers of monoolefins and diolefins with each other or with other vinyl monomers, such as, for example, ethylene/propylene, LLDPE and its mixtures with LDPE, propylene/butene-1, ethylene/hexene, ethylene/ethylpentene, ethylene/heptene, ethylene/octene, propylene/butadiene, isobutylene /isoprene, ethylene/alkyl acrylates, ethylene/alkyl methacrylates, ethylene/vinyl acetate (EVA) or ethylene/acrylic acid copolymers (EAA) and their salts (ionomers) and terpolymers of ethylene with propylene and a diene, such as hexadiene, dicyclopentadiene or ethylidenenorbornene; as well as mixtures of such copolymers and their mixtures with polymers mentioned above, for example polypropylene/ethylene-propylene copolymers, LDPE/EVA, LDPE/EAA, LLDPE/EVA and LLDPE/EAA.
Thermoplastic polymers may also include styrenic polymers, such as polystyrene, poly-(p-methylstyrene), poly-(α-methylstyrene), copolymers of styrene or. alpha. -ethylstyrene with dienes or acrylic derivatives, such as, for example, styrene/butadiene, styrene/acrylonitrile, styrene/alkyl methacrylate, styrene/maleic anhydride, styrene/butadiene/ethyl acrylate, styrene/acrylonitrile/methacrylate; mixtures of high impact strength from styrene copolymers and another polymer, such as, for example, from a polyacrylate, a diene polymer or an ethylene/propylene/diene terpolymer; and block copolymers of styrene, such as, for example, styrene/butadiene/styrene, styrene/isoprene/styrene, styrene/ethylene/butylene/styrene or styrene/ethylene/propylene/styrene. Styrenic polymers may additionally or alternatively include graft copolymers of styrene or α-methylstyrene such as, for example, styrene on polybutadiene, styrene on polybutadiene-styrene or polybutadiene-acrylonitrile; styrene and acrylonitrile (or methacrylonitrile) on polybutadiene; styrene and maleic anhydride or maleimide on polybutadiene; styrene, acrylonitrile and maleic anhydride or maleimide on polybutadiene; styrene, acrylonitrile and methyl methacrylate on polybutadiene, styrene and alkyl acrylates or methacrylates on polybutadiene, styrene and acrylonitrile on ethylene/propylene/diene terpolymers, styrene and acrylonitrile on polyacrylates or polymethacrylates, styrene and acrylonitrile on acrylate/butadiene copolymers, as well as mixtures of with the styrenic copolymers indicated above.
Nitrile polymers are also useful in the polymer composition of the invention. These include homopolymers and copolymers of acrylonitrile and its analogs such as methacrylonitrile, such as polyacrylonitrile, acrylonitrile/butadiene polymers, acrylonitrile/alkyl acrylate polymers, acrylonitrile/alkyl methacrylate/butadiene polymers, acrylonitrile/butadiene/styrene (ABS), and ABS which includes methacrylonitrile.
Polymers based on acrylic acids, include acrylic acid, methacrylic acid, methyl methacrylate acid and ethacrylic acid and esters thereof may also be used. Such polymers include polymethylmethacrylate, and ABS-type graft copolymers wherein all or part of the acrylonitrile-type monomer has been replaced by an acrylic acid ester or an acrylic acid amide. Polymers including other acrylic-type monomers, such as acrolein, methacrolein, acrylamide and methacrylamide may also be used.
Halogen-containing polymers may also be useful. These include resins such as polychloroprene, epichlorohydrin homopolymers and copolymers, polyvinyl chloride, polyvinyl bromide, polyvinyl fluoride, polyvinylidene chloride, chlorinated polyethylene, chlorinated polypropylene, fluorinated polyvinylidene, brominated polyethylene, chlorinated rubber, vinyl chloride-vinylacetate copolymer, vinyl chloride-ethylene copolymer, vinyl chloride-propylene copolymer, vinyl chloride-styrene copolymer, vinyl chloride-isobutylene copolymer, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-styrene-maleic anhydride tercopolymer, vinyl chloride-styrene-acrylonitrile copolymer, vinyl chloride-isoprene copolymer, vinyl chloride-chlorinated propylene copolymer, vinyl chloride-vinylidene chloride-vinyl acetate tercopolymer, vinyl chloride-acrylic acid ester copolymers, vinyl chloride-maleic acid ester copolymers, vinyl chloride-methacrylic acid ester copolymers, vinyl chloride-acrylonitrile copolymer and internally plasticized polyvinyl chloride.
Other useful thermoplastic polymers include homopolymers and copolymers of cyclic ethers, such as polyalkylene glycols, polyethylene oxide, polypropylene oxide or copolymers thereof with bis-glycidyl ethers; polyacetals, such as polyoxymethylene and those polyoxymethylene with contain ethylene oxide as a comonomer; polyacetals modified with thermoplastic polyurethanes, acrylates or methacrylonitrile containing ABS; polyphenylene oxides and sulfides, and mixtures of polyphenylene oxides with polystyrene or polyamides; polycarbonates and polyester-carbonates; polysulfones, polyethersulfones and polyetherketones; and polyesters which are derived from dicarboxylic acid and diols and/or from hydroxycarboxylic acids or the corresponding lactones, such as polyethylene terephthalate, polybutylene terephthalate, poly-1,4-dimethyliol-cyclohexane terephthalate, poly-[2,2,4-(4-hydroxyphenyl)-propane]terephthalate and polyhydroxybenzoates as well as block copolyetheresters derived from polyethers having hydroxyl end groups.
Polyamides and copolyamides which are derived from diamines and dicarboxylic acids and/or from aminocarboxylic acids or the corresponding lactams, such as polyamide-4, polyamide-6, polyamide-6/6, polyamide-6/10, polyamide-6/9, polyamide-6/12, polyamide-4/6, polyamide-11, polyamide-12, aromatic polyamides obtained by condensation of m-xylene, diamine and adipic acid; polyamides prepared from hexamethylene diamine and isophthalic and/or terephthalic acid and optionally an elastomer as modifier, for example, poly-2,4,4-trimethylhexamethylene terephthalamide or poly-m-phenylene isophthalamide may be useful. Further copolymers of the aforementioned polyamides with polyolefins, olefin copolymers, ionomers or chemically bonded or grafted elastomers; or with polyethers, such as for instance, with polyethylene glycol, polypropylene glycol or polytetramethylene glycols, and polyamides or copolyamides modified with EPDM or ABS may be used.
This invention has been described in detail with reference to specific embodiments thereof, including the respective best modes for carrying out each embodiment. It shall be understood that these illustrations are by way of example and not by way of limitation. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims. | The invention relates generally to an adjustable seat back and belt positioning juvenile booster car seat that folds compactly for easy transportation. | 1 |
FIELD OF THE INVENTION
The present invention relates to novel pharmaceutically useful organic compounds. These compounds are the pure enantiomeric forms, as well as the mixtures in any ratio of the two enantiomers of 2-phenyl-1,2-ethanediol carbamate compounds with at least one halogen substituent on the phenyl ring represented by the formulas (I), (II) and (III), wherein X may be at least one halogen atom substituted on the phenyl ring, excluding the racemic mixture of the compounds represented by the structural formulas (I) and (II). More particularly, the aforementioned compounds have been found to be effective in the treatment of central nervous system disorders, especially as anticonvulsants, neuroprotective agents and muscle relaxants. ##STR1##
DESCRIPTION OF THE PRIOR ART
Carbamate compounds of aryl alkyl alcohols have been known to be useful as antiepileptics and as muscle relaxants. It was reported in Toxicol. And Appl. Pharm. 2, 397-402 (1960) that when X is hydrogen in structural formula (I), the compounds is effective as an antiepileptic. Dicarbamate compounds of 2-methyl-3-propyl-1,3-propanediol has been reported and their pharmacological effects have been described in J. Pharmacol. Exp. Ther., 104, 229 (1952).
In U.S. Pat. No. 3,265,728, carbamate compounds represented by the structural formula (IV) with a substituent on the phenyl ring has been disclosed as useful in treating central nervous system disorders. In the structural formula (IV), R 1 is carbamate or methylene carbamate, R 2 is alkyl with 1-2 carbons, hydroxyalkyl with 1-2 carbons, hydroxy or hydrogen, R 3 is hydrogen, alkyl with 1-2 carbons and X is halogen atom comprising of fluorine, chlorine, bromine and iodine, methyl, methoxy, phenyl, nitro or amine group. ##STR2##
In U.S. Pat. No. 2,864,444, dicarbamate compounds from 2-phenyl-1,3-propanediol have been disclosed, and in U.S. Pat. No. 2,937,119 carbamate compounds such as isopropylmeprobamate have been disclosed.
The carbamate compounds described in the previous paragraph are currently being used in the treatment of central nervous system disorders, although efforts are being made to find new carbamate compounds for use in the treatment of various central nervous system diseases.
It is an object of the present invention to provide novel carbamate compounds for therapeutic use, especially compositions containing such carbamate compounds as the active ingredient, which possess therapeutic activity in treating diseases of the central nervous system.
SUMMARY OF THE INVENTION
In order to achieve the foregoing object, as well as other objects of the present invention, the carbamate compounds represented by the structural formulas (I), (II) and (III) have a chiral carbon on its benzylic position, hence there can be two optical enantiomers of the compounds represented by the structural formulas (I), (II) and (III). Generally speaking, optical enantiomers of various compounds exhibit different pharmacological and toxicological activities, and it is the current trend in the pharmaceutical industry to develop one enantiomer with either fewer toxicological effects or better efficacy.
This invention discloses the pure enantiomeric forms, as well as the mixtures in any ratio of the two enantiomers of 2-phenyl-1,2-ethanediol carbamate compounds with at least one halogen substituent on the phenyl ring represented by the formulas (I), (II) and (III), wherein X may be at least one halogen atom substituted at any positions on the phenyl ring including the ortho meta or para positions, excluding the racemic mixture of the compounds represented by the structural formulas (I) and (II), which are useful in the treatment of central nervous system diseases, particularly as antiepileptics, neuroprotective agents and centrally acting muscle relaxants.
DETAILED DESCRIPTION OF THE INVENTION
This invention provides novel pharmaceutically useful organic carbamate compounds represented by the structural formulas (I), (II) and (III), wherein X may be at least one halogen atom substituted at any positions on the phenyl ring including the ortho, meta or para positions. ##STR3##
The compounds of this invention possess selective pharmacological properties and are useful in treating and preventing central nervous system disorders including epilepsy, stroke and muscle spasm.
It will be apparent to those skilled in the art that the compounds of the present invention contain chiral centers. The compounds of formula (I), (II) and (III) contain an asymmetric carbon atom at the benzylic position, which is the aliphatic carbon adjacent to the phenyl ring. The therapeutic properties of the compounds may to a greater or lesser degree depend on the stereochemistry of a particular compound. The scope of the present invention includes all enantiomeric forms of formulas (I), (II) and (III), either in their pure form or as mixtures of enantiomers. Pure enantiomers as well as enantiomeric mixtures are within the scope of the present invention.
The carbamates compounds represented by the structural formulas (I) and (II) may be prepared by the synthetic method described in Scheme 1, a detailed description of which follows. A 2-phenyl-1,2-ethanediol with a halogen substituent on the phenyl ring is reacted with dimethyl carbonate in the presence of catalytic amount of sodium methoxide and the by-product methanol is removed by a vacuum distillation and the residual product is dried in vacuo. The crude reaction product is subsequently dissolved in a lower alkanol, such as methanol, and excess ammonium hydroxide (28-30%) is added to the reaction solution at room temperature to provide two regioisomeric forms of a monocarbamate of 2-phenyl-1,2-ethanediol with a halogen substituent on the phenyl ring. Regioisomeric forms of monocarbamates of 2-phenyl-1,2-ethanediol with a halogen substituent on the phenyl ring are separated by flash column chromatography.
In the structural formulas (I) and (II) in Scheme 1, X may be fluorine, chlorine, bromine or iodine atoms substituted at the ortho, meta or para positions of the phenyl ring.
The carbamate compounds represented by the structural formula (III) may be prepared by the synthetic method described in Scheme 2, and a detailed description of which follows. A 2-phenyl-1,2-ethanediol with a halogen substituent on the phenyl ring is dissolved in dichloromethane and is treated with 10 equivalents of sodium cyanate and 10 equivalents of methanesulfonic acid. The reaction mixture is stirred until the reaction is complete as evidenced by thin layer chromatography, and the mixture is washed with aqueous base solution, extracted with dichloromethane and the desired product is purified by flash column chromatography. ##STR4##
In the structural formulas (I) and (II) in Scheme 2, X may be a fluorine, chlorine, bromine or iodine atoms substituted at the ortho, meta or para positions of the phenyl ring. ##STR5##
In utilizing the compounds of the present invention for the treatment of diseases of the central nervous system, particularly the treatment of epilepsy, stroke and muscle spasm, it is preferred to administer the compounds orally. Since the compounds are well absorbed orally, it usually will not be necessary to resort to parenteral administration. For oral administration, the present carbamate compounds are preferably combined with a pharmaceutical carrier. The ratio of the carrier to the compounds of the present invention is not critical to achieve the effects of the medicine on the central nervous system, and they can vary considerably, depending on whether the composition is to be filled into capsules or formed into tablets. In tableting, it is usually desirable to employ at least as much pharmaceutical carrier as the pharmaceutically active ingredients. Various edible pharmaceutical carriers or mixtures thereof can be used. Suitable carriers, for example, are a mixture of lactose, dibasic calcium phosphate and corn starch. Other pharmaceutically acceptable ingredients can be farther added, including lubricants such as magnesium stearate.
A better under standing of the present invention may be obtained in light of following examples which are set forth to illustrate, but are not to be construed to limit, the present invention.
EXAMPLE 1
(D/L)-1-m-Chlorophenyl-1,2-ethanediol
In a 2 L 3 neck round bottom flask equipped with a mechanical stirrer, potassium osmate (52 mg), potassium ferricyanide (69.2 g), and potassium carbonate (29.02 g) were dissolved in t-butanol (300 mL) and deionized water (300 mL), and the mixture was cooled in an ice bath. To the reaction mixture m-chlorostyrene (9.74 g) was added and the reaction mixture was stirred for 18 hours at room temperature. After extracting with dichloromethane (200 mL), the combined organic phase was dried over anhydrous sodium sulfate, filtered and concentrated. (D/L)-1-m-Chiorophenyl-1,2-ethanediol (10.8 g, yield 90%) was purified by a flash column chromatography.
EXAMPLE 2
(D/L)-1-m-Chlorophenyl-1,2-ethanediol carbonate
In a 50 mL round bottom flask equipped with vacuum distillation apparatus, 1-phenyl-1,2-ethanediol (9.74 g), diethyl carbonate (10.25 mL) and sodium methoxide (305 mg) were placed and the resulting mixture was heated in an oil bath up to 135° C. with magnetic stirring. The by-product, ethyl alcohol was collected in a receiver flask. After collecting approximately 10 mL of ethanol, the residual ethyl alcohol remaining in the reaction mixture was removed by vacuum distillation. The reaction mixture was cooled to room temperature, dissolved in dichloromethane (40 mL), washed with brine (15 mL), dried over anhydrous sodium sulfate, filtered and then concentrated in vacuo to produce (D/L)-1-m-Chlorophenyl-1,2-ethanediol carbonate (11.05 g, yield 99%).
EXAMPLE 3
(D/L)-2-carbamoyloxy-1-m-chlorophenylethanol
In a 250 mL round bottom flask equipped with a magnetic stirrer, (D/L)-1-m-Chlorophenyl-1,2-ethanediol carbonate (10.95 g) was dissolved in methanol (60 mL) and the mixture was cooled in an ice bath. Ammonium hydroxide (30 mL, 28-30%) was added to the mixture and the mixture was stirred at room temperature for 1 hour or until the reaction was completed as evidenced by thin layer chromatography. Excess ammonium hydroxide and methanol were removed in vacuo to yield a white solid. (D/L)-2-Carbamoyloxy-1-m-chlorophenylethanol (1.25 g, yield 10%, m.p. 90° C.) was purified by flash column chromatography.
EXAMPLE 4
(D/L)-1-o-Chlorophenyl-1,2-ethanediol
(D/L)-1-o-Chlorophenyl-1,2-ethanediol (11.5 g, yield 90%, m.p. 109° C.) was prepared using the same synthetic method described in Example 1, except that o-chlorostyrene (10.21 g) was used instead of m-chlorostyrene
EXAMPLE 5
(D/L)-1-o-Chlorophenyl-1,2-ethanediol carbonate
(D/L)-1-o-Chlorophenyl-1,2-ethanediol carbonate (12.58 g, yield 100%) was prepared using the same synthetic method described in Example 2, except that (D/L)-o-chlorophenyl-1,2-ethanediol (10.98 g) was used instead of (D/L)-1-m-chlorophenyl-1,2-ethanediol.
EXAMPLE 6
(D/L)-2-carbamoyloxy-1-o-chlorophenylethanol and
(D/L)-2-carbamoyloxy-2-o-chlorophenylethanol
In a 200 mL round bottom flask equipped with a magnetic stirrer, approximately 12 mL of liquid ammonia was condensed at -78° C., and (D/L)-1-o-Chlorophenyl-1,2-ethanediol carbonate (6.0 g) in methanol (200 mL) was added slowly. The reaction mixture was slowly warmed to room temperature and was stirred at room temperature for another hour, and then concentrated in vacuo. (D/L)-2-Carbamoyloxy-1-o-chlorophenylethanol (1.97 g, yield 30%, m.p. 100° C.) and (D/L)-2-carbamoyloxy-2-o-chorophenylethanol (1.77 g) with minor impurities was obtained after a chromatographic purification. The impure (D/L)-2-carbamoyloxy-2-o-chorophenylethanol was treated in hot acetone and the resulting mixture was cooled to room temperature and filtered to yield analytically pure (D/L)-2-carbamoyloxy-2-o-chorophenylethanol (1.15 g, 18%, m.p. 183° C.).
EXAMPLE 7
(D/L)-2-Carbamoyloxy-2-o-chlorophenylethyl carbamate
(D/L)-1-o-Chlorophenyl-1,2-ethanediol was dissolved in tetrahydrofuran (115 mL) and sodium cyanate (9.0 g) and methanesulfonic acid (9.5 mL) was added in an ice bath. The resulting reaction mixture was stirred for 18 hours, extracted with tetrahydrofuran-dichloromethane mixture, washed with 5% aqueous sodium hydroxide, dried over sodium sulfate, filtered, concentrated and purified by flash column chromatography to yield a white solid. Analytically pure (D/L)-2-Carbamoyloxy-2-o-chlorophenylethyl carbamate (m.p. 190° C.) was obtained after recrystallization from ethanol-ether mixture.
EXAMPLE 8
(S)-1-o-Chlorophenyl-1,2-ethanediol
(S)-1-o-Chlorophenyl-1,2-ethanediol (11.45 g, yield 92%, m.p. 39° C., α! D =74.7 (c=2.75, methanol)) was prepared using the same synthetic method described in Example 4 except using hydroquinine 1,4-phthalazinediyl diether ((DHQ) 2 PHAL) (562 mg) was used instead of quinidine.
EXAMPLE 9
(S)-2-Carbamoyloxy-1-o-chlorophenylethanol
(S)-1-o-Chlorophenyl-1,2-ethanediol carbonate (12.58 g, yield 100%) was prepared using the same synthetic method described in Example 2 except that S-2-carbamoyloxy-1-o-chlorophenylethanol (10.98 g) was used instead of (D/L)-1-m-chlorophenyl-1,2-ethanediol. The (S)-2-carbamoyloxy-1-o-chlorophenylethanol prepared in this manner was used in the synthetic method described in Example 6 for (D/L)-1-m-chlorophenyl-1,2-ethanediol carbonate to yield (S)-2-carbamoyloxy-1-o-chlorophenylethanoI (4.68 g, yield 62%). An analytically pure sample of (S)-2-carbamoyloxy-1-o-chlorophenylethanol ethanediol (3.89 g, yield 52%, m.p. 133° C., α! D =64.9 (c=2.69, methanol)) was obtained by recrystallization from ethyl acetate.
EXAMPLE 10
(R)-1-o-Chlorophenyl-1,2-ethanediol
(S)-1-o-Chlorophenyl-1,2-ethanediol (11.45 g, yield 92%, m.p. 38° C., α! D =-64.5 (c=3.5, methanol)) was prepared using the same synthetic method described in Example 4, except that hydroquinidine 1,4-phthalazinediyl diether ((DHQD) 2 PHAL) (562 mg) was used instead of quinidine.
EXAMPLE 11
(R)-2-Carbamoyloxy-1-o-chlorophenylethanol
(R)-1-o-Chlorophenyl-1,2-ethanediol carbonate was prepared using the same synthetic method described in Example 2, except that (S)-2-carbamoyloxy-1-o-chlorophenylethanol (10.98 g) was used instead of (D/L)-1-m-chlorophenyl-1,2-ethanediol. The crude (R)-2-carbamoyloxy-1-o-chlorophenylethanol prepared in this manner was used in the synthetic method described in Example 6 for (D/L)-1-m-chlorophenyl-1,2-ethanediol carbonate to yield (R)-2-carbamoyloxy-1-o-chlorophenylethanol (4.02 g, yield 54%). An analytically pure sample of (R)-2-carbamoyloxy-1-o-chlorophenylethanol ethanediol (3.35 g, yield 45%, m.p. 133° C., α! D =-63.9 (c=2.22, methanol)) was obtained by recrystallization from ethyl acetate.
EXAMPLE 12
(S)-2-Carbamoyloxy-o-chlorophenylethyl carbamate
(S)-2-Carbamoyloxy-o-chlorophenylethyl carbamate (1.6 g, yield 35%, m.p. 167°-169° C., α! D =-84.1 (c=2.27, DMF)) was prepared using the same synthetic method described in Example 7, except that (S)-1-o-chlorophenyl-1,2-ethanol (3.0 g) was used instead of (D/L)-1-o-chlorophenyl-1,2-ethanediol.
EXAMPLE 13
(R)-2-Carbamoyloxy-o-chlorophenylethyl carbamate
(R)-2-Carbamoyloxy-o-chlorophenylethyl carbamate (2.1 g, yield 46%, m.p. 172°-174° C., α! D =84.9 (c=2.70, DMF)) was prepared using the same synthetic method described in Example 7, except that (R)-1-o-chlorophenyl-1,2-ethanol (3.0 g) was used instead of (D/L)-1-o-chlorophenyl-1,2-ethanediol.
The therapeutic use of the compounds of the present invention as anticonvulsants has been proven by the "Maximal ElectroShock (MES)" test, which is a well-established pharmacological screening method for anticonvulsants and the results are presented in Table I.
The procedure employed in the maximal electroshock test for anticonvulsants follows. The compound dosing solutions were prepared in saline, and the subjects, namely, mice (CF-1 strain), were dosed orally. After 1 hour, maximal electroshock were induced in mice via corneal electrodes using IITC Life Science model 11A Shocker at 50mA-60Hz for 0.2 second. Upon inducing maximal electroshock, the elimination of hindlimb tonic extension was considered as providing evidence of the protection by an anticonvulsant. The maximal electroshock test was performed at three different dose levels around the median efficacy dose (ED50) level of individual compound by using at least 8 mice in each group. ED50 value was calculated by the statistical method developed by Lichfield and Wilcoxon. Compounds with smaller ED50 value are more potent as anticonvulsant.
TABLE I______________________________________ ##STR6##Oral administration in miceCom-poundof Exam- X withple Position of Stereochemistry ED50No Chlorine Atom (*) Y (mg/Kg)______________________________________3 m-Cl (R/S)OH OCONH.sub.2 906 o-Cl (R/S)OCONH.sub.2 OH 1006 o-Cl (R/S)OH OCONH.sub.2 387 o-Cl (R/S)OCONH.sub.2 OCONH.sub.2 259 o-Cl (R)OH OCONH.sub.2 1311 o-Cl (S)OH OCONH.sub.2 5012 o-Cl (S)OCONH.sub.2 OCONH.sub.2 2213 o-Cl (R)OCONH.sub.2 OCONH.sub.2 16______________________________________
It is to be understood that the present invention is not to be considered as limited to the embodiments shown or described, as obvious modifications and equivalents will be apparent to those skilled in the art. | The pure enantiomeric forms, as well as enantiomeric mixtures excluding the racemic mixture of monocarbamates of 2-phenyl-1,2-ethanediol substituted with more than one halogen atom on the phenyl ring and dicarbamates of 2-phenyl-1,2-ethanediol substituted with more than one halogen atom on the phenyl ring have been found to be effective in the treatment of disorders of the central nervous system. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of the U.S. Provisional Application Ser. No. 60/169,345 filed Dec. 6, 1999 entitled GAS CLUSTER ION BEAM LOW MASS ION FILTER.
BACKGROUND OF THE INVENTION
This invention relates generally to gas cluster ion beam (GCIB) processing equipment, and, more particularly to incorporating means within GCIB processing equipment for eliminating monomer ions from the ion cluster beam without the production of unwanted heat.
The use of gas cluster ion beams for etching, cleaning, and smoothing of material surfaces is known in the art(see for example Deguchi et al., U.S. Pat. No. 5,814,194). For purposes of better understanding the present invention, gas clusters are nano-sized aggregates of materials that are gaseous under conditions of standard temperature and pressure. Such clusters typically consist of aggregates of˜several tens to˜several thousand atoms or molecules loosely bound to form the cluster. Such clusters can be ionized by electron bombardment or other means, permitting them to be formed into directed beams of known and controllable energy. The larger sized clusters are the most useful because of their ability to carry substantial energy per cluster ion, while having modest energy per atom or molecule. The clusters disintegrate on impact, with each individual atom or molecule carrying only a small fraction of the total cluster energy. Consequently the impact effects of large clusters are substantial, but are limited to a very shallow surface region. This makes ion clusters effective for a variety of surface modification processes, without the tendency to produce deeper subsurface damage characteristic of monomer ion beam processing.
Means for creation of and acceleration of such GCIB are described in the reference previously cited. Presently available ion cluster sources produce clusters ions having a wide distribution of sizes, N (where N=the number atoms or molecules in each cluster).
Because monomer ions as well as cluster ions are produced by presently available cluster ion beam sources, those monomer ions are accelerated and transported to the workpiece being processed along with the cluster ions. Upon acceleration in an electric field, monomers, having low mass, obtain high velocities that allow the light monomers to penetrate the surface of the workpiece and produce deep damage which is likely to be detrimental to the intended process. Such sub-surface ion damage is well-established and well-known from the more traditional monomer ion beam processing art and can produce a wide variety of deep damage and implantation.
It is also known in the ion cluster beam art that many GCIB processes benefit from incorporating means within GCIB processing equipment for eliminating monomer ions from the ion cluster beams. Electrostatic and electromagnetic mass analyzers have been employed to remove light ions from the beam of heavier clusters (see Knauer, U.S. Pat. No. 4,737,637 and Aoyanagi et al. in Japanese laid open application JP 03-245523A1 corresponding to Japanese application JP 2-43090, cited as prior art in Aoyagi et al., U.S. Pat. No. 5,185,287). Electrostatic and electromagnetic mass analyzers have also been employed to select ion clusters having a narrow range of ion masses from a beam containing a wider distribution of masses (see Knauer, U.S. Pat. No. 4,737,637 and Aoki, Japanese laid open application JP 62-112777A1).
In the past, electromagnetic beam filters have been used to separate ion masses. However, electromagnets are costly and, while in use, continually consume electrical power. Furthermore, the electrical power is converted to heat. Since the magnetic beam filter must be deployed in a vacuum chamber, namely the ionization/acceleration chamber, convection cooling of the beam filter is not practical. Generally, conductive paths to water or other fluid cooling systems must be provided and heat exchangers are required to remove heat from the cooling fluid and transfer it to the environment. Such cooling apparatus adds additional cost and introduces maintenance problems. The use of an electromagnetic beam filter is undesirable for these and other reasons.
It is therefore an object of this invention to reduce the heat produced in GCIB processing equipment and to eliminate the need for water or other cooling of a beam filter device.
It is a further object of this invention to separate undesired monomer ions from the GCIB.
It is still a further object of this invention to reduce the cost, weight, and maintenance complexity of a GCIB processing system
SUMMARY OF THE INVENTION
The objects set forth above as well as further and other objects and advantages of the present invention are achieved by the embodiments of the invention described hereinbelow.
The present invention is capable of reducing the heat produced in GCIB processing equipment, thus eliminating the need for water or other cooling of a beam filter device utilized therein. The invention utilizes a permanent magnet beam filter or a hybrid permanent electromagnetic beam filter to separate undesired monomer ions from the GCIB. Consequently the present invention substantially reduces the cost, weight, and maintenance complexity of a GCIB processing system over GCIB systems which incorporate a conventional electromagnetic beam filter system therein.
For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing a typical ion cluster size distribution for a GICB source;
FIG. 2 is a schematic that shows the basic elements of a prior art GCIB processing system;
FIG. 3 is a schematic that shows a GCIB processing system of this invention, with dipole magnet following beam formation and acceleration for separating undesired ions from the GCIB;
FIG. 4 is a schematic of a permanent dipole magnet for separation of undesired ions from a GCIB with the present invention;
FIG. 5 is a schematic geometric diagram to explain deflection in the magnetic beam filter of this invention;
FIG. 6 shows details of the GCIB and mass analysis plate of this invention under nominal beam conditions;
FIG. 7 shows details of the GCIB and the mass analysis plate of this invention under worst case beam alignment conditions;
FIG. 8 is a schematic geometric diagram showing GCIB beamlet separation in an example case of this invention;
FIG. 9 is a schematic of a hybrid permanent/electro-magnetic GCIB beam filter for use with the present invention;
FIG. 10 is a schematic diagram of controls for the hybrid permanent/electromagnetic GCIB beam filter of this invention; and
FIG. 11 is a schematic of the GCIB processing system of this invention employing the hybrid beam filter invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to understand better the present invention, the following information is directed toward typical ion cluster size distribution. FIG. 1 shows the typical ion cluster size distribution produced by a typical GICB source. The cluster formation process has been shown by N. Kofuji, et al., in “Development of gas cluster source and its characteristics”, Proc. 14 th Symp. on Ion Sources and Ion - Assisted Technology, Tokyo (1991), p. 15, to produce few small size clusters (values of N from 2 to about 10), but monomer ions (N−1) are produced in abundance as are larger clusters (N>a few tens, up to a few thousands.) It is known (Yamada, U.S. Pat. No. 5,459,326) that such atoms in a cluster are not individually energetic enough (on the order of a few electron volts) to significantly penetrate a surface to cause the residual surface damage typically associated with the other types of ion beam processing in which individual monomer atoms may have energies on the order of thousands of electron volts. Nevertheless, the clusters themselves can be made sufficiently energetic (some thousands of electron volts), to effectively etch, smooth or clean surfaces (see Yamada and Matsuo, in “Cluster ion beam processing”, Matl. Science in Semiconductor Processing I , (1998), pp 27-41).
FIG. 2 shows a typical configuration for a GCIB processor 100 of a form known in prior art, and which may be described as follows. A vacuum vessel 102 is divided into three communicating chambers, a source chamber 104 , a ionization/acceleration chamber 106 , and a processing chamber 108 . The three chambers are evacuated to suitable operating pressures by vacuum pumping systems 146 a, 146 b, and 146 c, respectively. A condensable source gas 112 (for example argon) is admitted under pressure through gas feed tube 114 to stagnation chamber 116 and is ejected into the substantially lower pressure vacuum through a properly shaped nozzle 110 . A supersonic gas jet 118 results. Cooling, which results from the expansion in the jet, causes a portion of the gas jet 118 to condense into clusters, each consisting of from several to several thousand weakly bound atoms or molecules. A gas skimmer aperture 120 separates the gas products that have not been formed into a cluster jet from the cluster jet so as to minimize pressure in the downstream regions where such higher pressures would be detrimental (e.g., ionizer 122 , high voltage electrodes 126 , and process chamber 108 ). Suitable condensable source gases 112 include, but are not necessarily limited to argon, nitrogen and other inert gases.
After the supersonic gas jet 118 containing gas clusters has been formed, the clusters are ionized in an ionizer 122 . The ionizer 122 is typically an electron impact ionizer that produces thermoelectrons from one or more incandescent filaments 124 and accelerates and directs the electrons causing them to collide with the gas clusters in the gas jet 118 , where the jet passes through the ionizer 122 . The electron impact ejects electrons from the clusters, causing a portion the clusters to become positively ionized. A set of suitably biased high voltage electrodes 126 extracts the cluster ions from the ionizer, forming a beam, then accelerates them to a desired energy (typically from 1 keV to several tens of keV) and focuses them to form a GCIB 128 . Filament power supply 136 provides voltage V F to heat the ionizer filament 124 . Anode power supply 134 provides voltage V A to accelerate thermoelectrons emitted from filament 124 to cause them to bombard the cluster containing gas jet 118 to produce ions. Extraction power supply 138 provides voltage V E to bias a high voltage electrode to extract ions from the ionizing region of ionizer 122 and to form a GCIB 128 . Accelerator power supply 140 provides voltage V Acc to bias a high voltage electrode with respect to the ionizer 122 so as to result in a total GCIB acceleration energy equal to V Acc . One or more lens power supplies ( 142 and 144 shown for example) may be provided to bias high voltage electrodes with potentials (V L1 and VL 2 for example) to focus the GCIB 128 .
A workpiece 152 , which may be a semiconductor wafer or other workpiece to be processed by GCIB processing, is held on a workpiece holder 150 , disposed in the path of the GCIB 128 . Since most applications contemplate the processing of large workpieces with spatially uniform results, a scanning system is desirable to uniformly scan the GCIB 128 across large areas to produce spatially homogeneous results. Two pairs of orthogonally oriented electrostatic scan plates 130 and 132 can be utilized to produce a raster or other scanning pattern across the desired processing area. When beam scanning is performed, the GCIB 128 is converted into a conical scanned GCIB 148 , which scans the entire surface of workpiece 152 .
The present invention relies upon the understanding that GICB sources, including the one described in FIG. 1, produce a broad distribution of ion cluster sizes with limited cluster ion currents available. Therefore it is not practical to perform GICB processing by selecting a single cluster size or a narrow range of cluster sizes—the available fluence of such a beam is too low for productive processing. It is preferred to eliminate only the monomer ions and other lowest mass ions from the beam and use all remaining heavier ions for processing. It has been determined by the present invention that it is sufficient to provide filtering to eliminate monomer ions while depending on cluster size distribution characteristics shown in FIG. 1 to limit the small clusters (N=2 to ˜10) in the beam. Clusters of size N>10 are adequately large to provide acceptable results in most processes. Since the typical cluster distribution contains clusters of up to N=several thousand and there are few clusters of mass less than 100, it is not significantly detrimental if clusters up to size 100 are removed from the beam in the process of eliminating the monomer ions.
The present invention further relies upon the understanding that a magnet can be used to provide a magnetic field appropriate for separating monomer ions from a GCIB having a distribution of ion cluster sizes similar to that shown in FIG. 1 . FIG. 3 shows GCIB apparatus having such a magnetic beam filter 250 placed in a location after beam formation by high voltage electrodes 126 and before and before beam scanning at electrostatic scan plates 130 and 132 . The GCIB 128 containing unwanted monomer ions passes through a magnetic B field between pole faces of permanent magnet assembly 250 , where the lighter monomer ions are deflected away from the initial trajectory of GCIB 128 . The light monomer ions follow deflected trajectory 264 , while the heavy cluster ions are negligibly perturbed and follow trajectory 262 , which is substantially the same as the initial trajectory of GCIB 128 . The unwanted monomer ions following deflected trajectory 264 strike mass analysis plate 210 , which has an aperture to permit passage of the heavy cluster ions following trajectory 262 . In order to ensure that the beam trajectories in the magnetic beam filter are predictable, it is important that the entire radial extents of the portions of the GCIB following trajectories 128 , 262 , and 264 be substantially within the uniform magnetic field region of the magnetic beam filter 250 . In some cases it may be desirable to limit the diameter or size of the incoming GCIB 128 in order to assure this condition. In such case, an upstream beam defining aperture 209 may be included to collimate the GCIB 128 prior to entry into the magnetic beam filter 250 .
Because effective GCIB processing can be accomplished at energies of 30 keV and lower, and because the monomer ions are typically of relatively low mass, for example AMU 40 for argon, powerful magnetic B fields are not required to effectively separate the monomer ions from the GCIB. Furthermore, since it is acceptable with the present invention to remove other higher mass (N<100) clusters from the GCIB, it is practical to use a fixed magnetic B field. A permanent magnet can be used effectively within the GCIB apparatus of the present invention. FIG. 4 shows detail of a permanent magnet beam filter 250 .
More specifically, as shown in FIG. 4, permanent magnet beam filter 250 comprises permanent magnet 252 having north (N) and south (S) poles. Iron pole pieces 254 and 256 are attached to permanent magnet 252 forming a magnetic circuit having a two pole faces 266 and 268 separated by a gap, having within it a magnetic B-field 258 signified by an arrow and the symbol B. Pole face 266 is the north pole face and pole face 268 is the south pole face. The permanent magnet beam filter 250 is disposed such that the GCIB 128 trajectory 260 passes centrally through the gap between pole faces 266 and 268 . Light monomer ions are deflected along trajectory 264 and the heavy cluster ions continue substantially unperturbed along trajectory 262 which differs negligibly from trajectory 260 . The permanent magnet beam filter 250 does not produce heat.
FIG. 5 shows a diagram to explain the deflection that occurs in such a filter. Referring to FIG. 5, south pole face 268 is seen from the direction of north pole face 266 (not shown). A GCIB enters from the left on initial trajectory 260 . The GCIB has an ion size distribution similar to that shown in FIG. 1 and includes positive ion clusters as well as positive monomer ions and is assumed to have been formed and accelerated in the GCIB apparatus of this invention, a type of which is shown in FIG. 3. A magnetic flux (B-field) exists in the gap between the two pole faces and is symbolized by B and the circled cross, which means that the direction of the B-field is into the plane of the paper (from the north pole face to the south pole face). The width of the pole face 268 in the direction of the trajectory 260 is signified by the lower case letter “l”. In the magnetic field, which is assumed to be uniform within the gap and zero outside the gap, the positive monomer ions travel in a circular path of radius “R” and exit the magnetic gap along deflected trajectory 264 . Heavy cluster ions are not substantially perturbed and exit the magnetic gap along trajectory 262 which is substantially the same as trajectory 260 .
Cluster ions having small sizes of N=2, 3, . . . if present, follow trajectories between monomer ion trajectory 264 and heavy cluster trajectory 262 . After exiting the magnetic gap and drifting an additional distance “L”, the trajectories 264 and 262 are separated by distance “d” referred to as the “deflection” of the monomer ion beam. R = 2 · m · V e B Eqn . 1
Equation 1 is the well-known equation of motion of a charged particle, having a single electrical charge, in a magnetic field where:
R is the radius of the circular orbit of the charged particle
B is the magnetic B-field strength
m is the mass of the charged particle
V is the energy in electron volts of the charged particle, which for a singly charged ion, equals the total potential, V Acc , through which it has been accelerated.
e is the magnitude of the charge of a single electron (charge quantum)
Equation 2 is obtained from the geometry of FIG. 5 . 1 R = sin θ , Eqn . 2
where 1 is the width of pole face 268
Equation 3 is obtained by solving Eqn. 2 for the deflection angle, θ and substituting Eqn. 1 for R. θ = a sin [ 1 · B 2 · m · V e ] Eqn . 3
Equation 4 is obtained from the geometry of FIG. 5 .
d=L· tan θ+ R− {square root over (( R 2 −l 2 ))} Eqn. 4
The total deflection d is the sum of the deflection occurring in the magnet gap and the additional drift after exiting the magnet gap.
Equation 5 results from substituting the expression for θ from Eqn. 3 into Eqn. 4 and simplifying. d = B · L · 1 2 · V · m - B 2 · e · l 2 e + ( 2 · V · m B ) B - 2 · V · m - B 2 · e · l 2 e B Eqn . 5
Eqn. 5 gives the total deflection “d” given the magnet and drift geometry and the magnetic B-field strength, neglecting magnetic field fringing effects. By using Eqn. 5 and solving by indirect means it is possible to determine the required value of B, magnetic B-field strength required to produce a desired deflection d in a given geometry and for a specific particle and energy.
The actual separation of the deflected monomer beam from the desired heavy cluster beam occurs at the mass analysis plate 210 . FIG. 6 shows an example mass analysis plate 210 for illustration. Mass analysis plate 210 has a slit-like aperture 270 through which the desired heavy cluster beam trajectory may pass. Because there may be aberrations in the beam forming optics of a GCIB forming system, it is generally the case that in a GCIB containing monomer ions, the beam diameter of the beam of desired heavy cluster ions may be different from the diameter of the beam of co-traveling monomer ions. This is illustrated in FIG. 6 by the fact that the beam spot size 274 of the monomer ion beam where it strikes the plate 210 is different from the spot size 272 of the heavy cluster ion beam where it passes through the plane of the plate 210 . The respective beam spot sizes may be measured or determined by mathematical modeling by those skilled in the arts. The addition of upstream beam defining apertures may be employed to control the maximum size of the beam spot sizes.
If the heavy cluster ion beam spot radius is R H and the monomer ion spot radius is R M , and the maximum misalignment (circular error) of the center of the analysis aperture 270 with respect to the beam is ε then the aperture slit width must be greater than the beam diameter. Additionally, for tolerance reasons, it may desirable to allow an additional amount δ, to the slit width. In such case, the slit width will be:
A= 2 R H +2ε+δ Eqn. 6
and the necessary separation between the centers of the monomer and heavy beam spots to assure complete separation under worst case alignment conditions is:
d=R H +2ε+δ/2+ R M Eqn. 7
FIGS. 6 and 7 shows the geometry for beam separation with slit width A and beam deflection d designed according to Equations 6 and 7 in the case (FIG. 6) where there is no misalignment of the beam to the aperture, and in the case (FIG. 7) where there is worst case misalignment.
As an example case, consider the GCIB processor of apparatus 200 shown in FIG. 3, wherein the permanent magnet beam filter 250 has a pole face width, l=2″ and the drift distance L from the magnet 250 to the mass analysis plate 210 is 8″. The monomer spot size 274 is 0.7″ and the heavy cluster ion beam spot size 272 is 0.3″. Alignment error, ε is 0.05″ and we choose δ to be 0.1″. We have:
l=2″
L=8″
R M =0.35″
R H =0.15″
from Eqn. 6: A=0.5″
from Eqn. 7: d=0.65″
the beam is a 30 keV argon GCIB having zero alignment error from Eqn. 5:, solving implicitly, given d
B≈0.2237 tesla=2237 gauss
and the trajectories of the monomer and heavy cluster ion beamlets are as shown in FIG. 8 .
The monomer beamlet is deflected by approximately 4.13° from the heavy cluster ion beamlet. All of the heavy cluster beamlet, following trajectory 262 passes through the slit 270 in the mass analysis plate 210 , while all of the monomer ion beamlet, following trajectory 264 strikes the mass analysis plate 210 .
A problem, however, may still, under certain circumstances, exist with the use of a permanent magnet beam filter for separation of monomer ions from a GCIB. Occasionally, for beam diagnostic purposes, it may be desirable to transmit the entire beam including any monomer ions present (for example to determine the ratio of monomer ions to cluster ions for the source, as may be required to tune the source to minimize the production of monomer ions). In such case, it is desirable to remove the beam filter effect, but because of the permanent magnet nature of the filter this will only be straightforwardly achieved by removal of the entire beam filter from the system, which is not a practical method from a point of maintenance effort and equipment availability.
A further embodiment of this invention is directed to the above problem. In this embodiment of this invention a novel combination of permanent magnet and electromagnet is incorporated within the GCIB apparatus 200 shown in FIG. 3 . FIG. 9 shows a hybrid permanent/electromagnetic beam filter 300 , made by adding an exciting coil to the permanent magnet beam filter 250 described in FIG. 4 . Specifically, permanent/electromagnetic beam filter 300 comprises a permanent magnet 252 having north (N) and south (S) poles. Iron pole pieces 254 and 256 are attached to permanent magnet 252 forming a magnetic circuit having a two pole faces 266 and 268 separated by a gap, having within it a magnetic B-field 258 signified by an arrow and the symbol B. Pole face 266 is the north pole face and pole face 268 is the south pole face. The permanent/electromagnetic beam filter 300 is disposed such that the GCIB 128 trajectory 260 passes centrally through the gap between pole faces 266 and 268 . Light monomer ions are deflected along trajectory 264 and the heavy cluster ions continue substantially unperturbed along trajectory 262 which differs negligibly from trajectory 260 . Permanent magnet 252 is chosen to have a magnetic strength at least great enough to produce a B-field 258 in the gap that is large enough to provide a desired minimum deflection of light monomer ions trajectory 264 from the heavy cluster ions trajectory 262 sufficient to separate the monomer ions from the transmitted beam of heavy cluster ions under conditions of maximum beam energy and for the heaviest monomer ions that will be used (for example argon, AMU 40 ), and under conditions of worst case beam alignment. Permanent/electromagnetic beam filter 300 also has an electrical excitation coil 302 , which can be energized by power supply/controller 308 to provide an electromagnetic B-field to oppose and counteract the permanent magnet produced B-field in the gap, thus rendering the gap B-field 258 substantially equal to zero, during the time while the coil 302 is thus suitably energized. The characteristics of the coil and power source are chosen to provide sufficient ampere-turns to produce a B-field 258 in the gap which is at least greater than that provided by the permanent magnet 252 . The method of calculating the proper number of ampere-turns to produce a desired B-field is well known and may be found in various references including M. S. Livingston, et al., Particle Accelerators , p. 242, eqn. (8-5), McGraw-Hill, New York (1962). When the coil 302 is not energized, the permanent magnet 252 provides the predetermined B-field 258 in the gap, and when the coil 302 is suitably energized, the B-field 258 in the gap is zero. When the coil 302 is not energized, the permanent/electromagnetic beam filter 300 does not produce heat.
To facilitate adjustment of the gap B-field 258 to zero value, a magnetic field sensor 304 may be disposed in the gap to measure the gap B-field 258 . Such a sensor may be a small Hall-effect sensing device and is so disposed as to sense the B-field 258 without interfering with the transmission of the GCIB through the magnet gap.
During the time the coil 302 is energized to disable the beam filter, resistive heating heats coil 302 . The coil 302 may be encapsulated and may be in thermal contact with the magnet pole piece 256 and heat produced by the coil may be conducted into the encapsulation and pole piece to allow short periods of operation without excessive temperature rise due to the combined heat capacity of coil, encapsulation, and pole pieces. As a safety measure, temperature sensor 306 , which may be a bi-metallic thermostat, a thermistor, a thermocouple, or the like, may be attached to the coil 302 and connected by cable 312 to power supply/controller 308 . Signals from temperature sensor 306 are used by power supply/controller 308 to shut down the coils 302 , in the event that an excessive temperature rise is detected in coil 302 .
FIG. 10 shows details of the controls for the hybrid permanent/electromagnetic beam filter. Cable 312 connects power supply/controller 308 to coil 302 , magnetic field sensor 304 , and temperature sensor 306 . Operation is as follows: a system control device 310 which may be a small computer or microcomputer provides a magnetic B-field set-point signal 326 corresponding to zero magnetic B-field and power supply enabling signal 324 to power supply/controller 308 . Signals 324 and 326 are connected through cable 314 . When power supply enabling signal 324 does not enable power supply/controller 308 , switch device 320 disconnects coil 302 from power amplifier 318 , de-energizing coil 302 .
When power supply enabling signal 324 enables power supply/controller 308 , switch device 320 connects coil 302 to the output of power amplifier 318 , energizing coil 302 . Set-point signal 326 is compared to the signal from magnetic field sensor 304 at error amplifier 316 , producing an error signal which drives power amplifier 318 to deliver current through switch device 320 to coil 302 . Current in the coil 302 increases until feedback from magnetic field sensor 304 compares with the zero field set-point signal 326 , and regulates the B-field in the magnet gap to zero. System control device 310 limits the duty cycle of enabling power supply/controller 308 to a predetermined value that does not produce excessive heating of coil 302 .
Temperature sensor 306 monitors coil temperature as a protective measure against system control device failure. If temperature sensor detects a coil over-temperature condition, it overrides control inputs to switch device 320 , shutting down power to coil 302 . If temperature sensor 306 is a low level analog device such as a thermistor or thermocouple, amplifier 322 may be employed to create a control level signal for switch device 320 from the low level sensor signal.
FIG. 11 shows the GCIB processing system or apparatus 400 of this invention with the hybrid permanent/electromagnetic beam filter invention. During normal beam operation of the GCIB processing device, system control device 310 does not enable the coil 302 and the hybrid permanent/electromagnetic beam filter 300 filters low mass monomer ions from the beam by virtue of it's permanent magnetic B-field. During periods of beam diagnostic tests, the system control device 310 , enables the power supply control device 308 and sets current in the electromagnet coil 302 to zero the field in the magnet gap, disabling the beam filter and permitting the entire GCIB including monomer ions, if present, to be transmitted through the system. During normal beam processing, no heat is generated in the beam filter. During diagnostic testing, heat is generated in the beam filter but is limited to a safe duty cycle.
Although the invention has been described with respect to various embodiments, it should be realized this invention is also capable of a wide variety of further and other embodiments within the spirit and scope of the appended claims. | Incorporating the use of a permanent magnet within a GCIB apparatus to separate undesirable monomer ions from a gas cluster ion beam to facilitate improved processing of workpieces. In an alternate embodiment, the effect of the permanent magnet may be controlled by the use of an electrical coil. The above system eliminates problems related to power consumption and heat generation. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a filing under 35 U.S.C. 371 of International Application No. PCT/GB2009/000776 filed Mar. 24, 2009, entitled “Process for the Preparation of Donepezil Hydrochloride,” claiming priority of Indian Patent Application No. 636/MUM/2008 filed Mar. 25, 2008, which applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
The present invention relates to an improved process for the preparation of highly pure donepezil hydrochloride. More, particularly, the present invention relates to an improved process for the preparation of donepezil hydrochloride using a novel reduction step carried out using at least one hydrogenation catalyst, in the presence of ionic compounds in organic solvents or an aqueous solvent or mixture thereof from 1-benzyl-4-[5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide. More particularly, the invention relates to an industrially suitable process for the preparation of donepezil hydrochloride.
BACKGROUND OF THE INVENTION
Donepezil hydrochloride, which is chemically known as 1-benzyl-4-[(5,6-dimethoxy-1-indanon)-2-yl)methyl piperidine hydrochloride [formula I]
is used in the treatment of Alzheimer's disease where it is used to increase cortical acetylcholine. It is available for oral administration in film-coated tablets containing 5 or 10 mg of donepezil hydrochloride.
Donepezil hydrochloride is well known in the art and was first disclosed in U.S. Pat. No. 4,895,841, hereinafter referred to as the '841 patent. As described therein, donepezil hydrochloride is prepared by reacting 5,6-dimethoxy-1-indanone with 1-benzyl-4-formylpiperidine in the presence of a strong base such as lithium diisopropyl amide followed by a reduction step (Examples 3 and 4) with a palladium carbon catalyst in tetrahydrofuran (THF). The residue was purified by making use of silica gel column chromatography. This process, however, suffers from certain evident limitations. The procedure laid down for reduction of 1-benzyl-4-[(5,6-dimethoxy-1-indanon)-2-ylidenyl]methyl piperidine is not industrially feasible. It entails the use of column chromatography for the purification of the hydrogenated residue, which cannot be carried out industrially. Further, the process makes use of THF, which is a highly flammable solvent and may form explosive peroxide vapors. Moreover, the overall yield of donepezil HCl is reported to be 50.8%. The purity of the product obtained is not disclosed in the patent.
U.S. Pat. No. 5,606,064, hereinafter referred to as the '064 patent, and U.S. Pat. No. 6,252,081 describe a process for the preparation of donepezil wherein 1-benzyl-4-(5,6-dimethoxyindan-1-on-2-ylidene)methyl pyridinium salt is reduced to yield donepezil. The reduction of the olefinic bond and a pyridinium ring in the presence of a benzyl group is difficult to achieve under the conditions disclosed in the patent. Further, the reaction requires at least 24 hours to complete (Example 6).
The major disadvantage of the process is that the reaction is carried out in the presence of methanol and platinum dioxide. The use of an expensive catalyst is not viable industrially. Moreover, on repeating the above process, unwanted side products are produced, such as a partly hydrogenated impurity of formula III
which is formed to an extent of 5%. This impurity is difficult to separate in the final crystallization, hence requires purification by column chromatography/repeated purification resulting in poor yield, hence making the process not feasible on an industrial scale. These impurities also affect the overall yield of the final product. Further, the purity of the product obtained is not disclosed in the patent.
U.S. Pat. No. 6,649,765 and US Patent Application published under no. 2004/0158070A1 describe the reduction of 5,6-dimethoxy-2-(pyridin-4-yl)methylene-indan-1-one using a noble metal oxide catalyst (platinum oxide) in a mixture of solvents such as acetic acid and methanol at 10-45 psi gauge pressure followed by benzylation to obtain donepezil hydrochloride. Besides making the process expensive, it is not industrially viable. Further, the purity of the product obtained is not disclosed in these patents.
PCT Publication No. WO2004/082685 describes the preparation of donepezil which comprises a two-step reduction starting from 5,6-dimethoxy-2-(pyridine-4-yl)methylene-indan-1-one via the preparation of intermediate 5,6-dimethoxy-2-(4-pyridyl)methyl-indan-1-one using methanol as one of the solvents followed by benzylation.
The above process is also time consuming and difficult to carry out as it involves multiple steps.
US Patent Application published under the No. 2007/0135644A1 discloses the preparation of donepezil hydrochloride by reducing 5,6-dimethoxy-2-[1-(4-pyridinyl)methylidene]-1-indanone tosylate with 10% Pd/C catalyst in demi-water at 70-95° C., at 10 bar for 8 hours. The mixture is extracted three times with 1-butanol to afford a residue which is purified with methyl-tert-butyl ether to obtain 5,6-dimethoxy-2-(4-piperidinylmethyl)-1-indanone, followed by condensation with benzyl chloride in toluene for 8 hours at 145° C. to yield donepezil which is further converted to donepezil hydrochloride.
This process involves reduction at a high pressure of 10 bar and temperature of 70-95° C. which leads to impurities. Further, the benzylation reaction requires a high temperature of 145° C. for 8 hours. The work-up process is very lengthy thereby making the whole process industrially unfavorable.
PCT Publication No. WO 2008/010235 discloses a method for preparation of donepezil hydrochloride wherein 1-benzyl-4-[(5,6-dimethoxy-1-indanon)-2-ylidenyl]methyl piperidine, is reduced with metal borohydride in the presence of a catalytic amount of a cobalt salt in a large volume of THF as solvent to yield donepezil hydrochloride. This process is not viable industrially due to use of costly cobalt catalyst.
The prior art procedures for the preparation of donepezil have certain disadvantages, such as multiple reduction steps, and/or chromatographic separation of intermediates, side-product formation, giving low yields. These properties hinder the large-scale production of donepezil hydrochloride.
Therefore, there is a need to develop an industrially feasible, cost effective and environmentally friendly process for the preparation of donepezil hydrochloride of formula (I) with high purity.
OBJECTS OF THE INVENTION
An object of the present invention is to provide an improved reduction procedure for the preparation of donepezil hydrochloride, which is safe, industrially feasible, time efficient, cost effective and which provides donepezil hydrochloride in high yield and purity.
Another object of the invention is to minimize the partial debenzylation of donepezil to the impurity of formula (III) which forms during the reduction.
The invention is hereinafter detailed in details, no part of which may be construed as restrictive to the scope of the instant invention.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a process for preparing donepezil or a salt thereof, the process comprising reducing a 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium halide of formula II
wherein X is bromide or chloride, in the presence of an ionic compound, a solvent, a catalyst and a source of hydrogen, to form donepezil and optionally converting the donepezil to the salt thereof. It will be appreciated that, compared to some of the multistep processes of the prior art, the process of the present invention is very simple, so is very suitable for industrial application.
In an embodiment, compound II is 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide having the following structure.
In an alternative embodiment, compound II is 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium chloride having the following structure.
In an embodiment, the donepezil is converted to the salt thereof. Suitable salts are well known to those skilled in the art, and the process for preparing the salt would also be well known to those skilled in the art. Preferably, the process comprises converting donepezil to donepezil hydrochloride. The donepezil may be reacted with hydrochloric acid to form donepezil hydrochloride. The hydrochloric acid may be in the form of a methanolic solution. It will be appreciated that the process of the present invention may be a process for preparing a salt of donepezil, other than the hydrochloride salt. In which case, an acid other than hydrochloric acid would be present during the reaction. For example, formation of the hydrobromide salt would involve hydrobromic acid being present during the reduction.
The ionic compound may be an inorganic compound that is a solid at room temperature (20° C. to 25° C.). The ionic compound may also be a liquid, organic salt whose melting point is below 100° C. In an embodiment, the ionic compound is selected from the group consisting of a quaternary ammonium salt, a salt of an alkali metal, a salt of an alkaline earth metal, a formate, a perchlorate or mixtures thereof. The alkali metal may be sodium or potassium. The alkaline earth metal may be calcium. Typically, the ionic compound is selected from the group consisting of ammonium acetate, ammonium chloride-ammonium hydroxide, ammonium citrate, ammonium tartrate, calcium phosphate, citrate, phosphate, potassium phosphate, potassium acetate, potassium chloride, potassium citrate, sodium acetate, sodium chloride, triethylammonium formate, pyridinium formate, and sodium perchlorate. Preferably, the ionic compound is ammonium acetate.
The solvent may be an organic solvent, an aqueous solvent or mixtures thereof. The solvent may be a C 1 to C 3 alcohol. The solvent may be an ether. In an embodiment, the solvent is selected from the group consisting of methanol, ethanol, isopropyl alcohol, diethyl ether, diisopropyl ether, t-butyl methyl ether, tetrahydrofuran (THF), ethyl acetate, methylene chloride, ethylene chloride, rectified spirit, acetic acid, and mixtures thereof. Preferably, the solvent is a mixture of acetic acid, ethyl acetate, and rectified spirit.
In an embodiment, the catalyst is selected from the group consisting of palladium, palladium hydroxide, palladium on activated carbon, palladium on alumina, platinum, platinum on activated carbon, ruthenium, rhodium, and Raney nickel. Preferably, the catalyst is platinum on activated carbon.
Preferably, the process is a process for preparing donepezil hydrochloride, the ionic compound is ammonium acetate, the solvent is a mixture of acetic acid, ethyl acetate, and rectified spirit and the catalyst is platinum on activated carbon.
Suitably, the source of hydrogen is hydrogen gas. In an embodiment, the reduction reaction is carried out at a hydrogen gas pressure ranging from about 25 psi to about 80 psi, preferably from about 55 psi to about 60 psi.
Typically, the reduction reaction is carried out at a temperature ranging from about 10° C. to about 50° C., preferably from about 25° C. to about 30° C.
In an embodiment, the reduction reaction is carried out for a period of time ranging from about 2 hours to about 6 hours, preferably from about 3 hours to about 4 hours.
In an embodiment, the process of the present invention is a process for preparing donepezil free base, and the process further comprises converting the donepezil free base to a salt of donepezil following the reduction reaction.
The product of the reduction step may be purified for example by crystallization using a solvent or mixture of solvents.
According to another aspect of the present invention, there is provided donepezil hydrochloride having a purity of at least 98%, preferably at least 99%.
According to another aspect of the present invention, there is provided donepezil or a salt thereof, for example donepezil hydrochloride, prepared according to the process described above.
Preferably, the donepezil or salt thereof contains less than 0.1% of impurity of formula III,
preferably, less than 0.01% of impurity of formula III.
According to another aspect of the present invention, there is provided a pharmaceutical formulation comprising donepezil or a salt thereof as described above, together with one or more pharmaceutically acceptable excipients. Such excipients and formulations would be well known to those skilled in the art. The formulation may also include other active pharmaceutical ingredients.
According to another aspect of the present invention, there is provided the use of donepezil or a salt thereof as described above or a pharmaceutical formulation as described above, in medicine.
According to another aspect of the present invention, there is provided the use of donepezil or a salt thereof as described above or a pharmaceutical formulation as described above, in the treatment of a disease state prevented, ameliorated or eliminated by the administration of a cholinesterase inhibitor. In an embodiment, the disease is Alzheimer's disease.
According to another aspect of the present invention, there is provided a method of treating a disease state prevented, ameliorated or eliminated by the administration of a cholinesterase inhibitor in a patient in need of such treatment, which method comprises administering to the patient a therapeutically effective amount of donepezil or a salt thereof as described above. In an embodiment, the disease is Alzheimer's disease.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an improved reduction process for the synthesis of donepezil hydrochloride, which process is safe, industrially-feasible, time and cost effective and reduces the multiple steps of reduction during the preparation of donepezil hydrochloride compared to the prior art. In an embodiment, the process involves the use of the intermediate 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide for the production of donepezil hydrochloride. In another embodiment, the process involves the use of the intermediate 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium chloride for the production of donepezil hydrochloride.
The term “donepezil” as used herein refers to all forms of donepezil inclusive of polymorphs thereof, for example, amorphous donepezil or crystalline donepezil. The donepezil may also be in the form of a hydrate, or a solvate thereof.
In an embodiment, the term “ionic compound” as used herein refers to an inert substance that minimizes changes in the pH of a solution. The ionic compound may thereby control the impurity formation during the reaction and may enhance the rate of reaction. The ionic compound may prevent changes in the acidity of a solution when an acid or base is added to the solution, or when the solution is diluted. Ionic compounds include ionic liquids and solids. While ionic inorganic compounds are solids at room temperature, organic ionic liquids may be salts whose melting point are relatively low (below 100° C.).
These ionic compounds not only have the potential to increase chemical reactivity and thus lead to a more efficient process, they are also non-flammable and are less toxic than conventional solvents due to their low vapor pressure.
It has been found that the yield of donepezil hydrochloride is substantially increased by using the process of the present invention, as a number of impurities formed are reduced due to the modified reduction step, thus the reaction becomes simpler and more easily achievable on an industrial scale.
In an embodiment, the overall scheme of reactions followed in the present invention is depicted below:
According to the invention, there is provided a process for the preparation of donepezil hydrochloride, comprising: catalytic hydrogenation of 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide or chloride in the presence of an ionic compound and suitably using an organic solvent, or an aqueous solvents or mixtures thereof.
The ionic compound for use in a process according to the present invention may be selected from the group consisting of ammonium acetate, ammonium chloride-ammonium hydroxide, ammonium citrate, ammonium tartrate, calcium phosphate, citrate, phosphate, potassium phosphate, potassium acetate, potassium chloride, potassium citrate, sodium acetate, sodium chloride, triethylammonium formate, pyridinium formate, sodium perchlorate, and triethylammonium formate. The ionic compound may be used alone or in combination with other ionic compounds known to a person skilled in the art. A preferred ionic compound is ammonium acetate. Ammonium acetate may be added to maintain the pH of the reaction mixture thereby making the reaction faster and reducing the formation of the impurity of formula III.
A preferred catalyst for use in a process according to the present invention may be selected from the group consisting of palladium, palladium hydroxide, palladium on activated carbon, palladium on alumina, platinum, platinum on activated carbon, ruthenium, rhodium, and Raney nickel. In the process of the present invention, platinum on activated carbon is the most preferred catalyst. A combination of catalysts may also be used.
In an embodiment, the solvent is selected from the group consisting of methanol, ethanol, isopropyl alcohol, diethyl ether, diisopropyl ether, t-butyl methyl ether, tetrahydrofuran (THF), ethyl acetate, methylene chloride, ethylene chloride, rectified spirit, acetic acid, or mixtures thereof. Suitably, the solvent is a mixture of solvents. Preferably, the solvent is a mixture of acetic acid, ethyl acetate, and rectified spirit. As used herein, rectified spirit refers to ethanol which has been denatured by means of 5% methanol.
The reduction reaction is preferably carried out at a hydrogen gas pressure ranging from about 25 to about 80 psi, more preferably from about 55 to about 60 psi. The reduction reaction is preferably carried out at a temperature ranging from about 10 to about 50° C., more preferably about 25 to about 30° C. The reduction reaction is preferably carried out for a period of time ranging from about 2 to about 6 hours, more preferably about 3 to about 4 hours. These conditions are to be contrasted with the high pressure of 10 bar and high temperature of 70-95° C. as reported in the prior art; thus the present invention reduces reaction time, minimizes impurity levels and subsequently increases the yield.
It has been observed that donepezil of formula I obtained by the process of the present invention is highly pure. The term “highly pure” as used herein means a compound having HPLC purity of at least 98%, preferably at least 99%, typically around 99.8%. Preferably, donepezil obtained by following the process of the present invention is substantially free of the impurity of formula (III). The term “substantially free” as used herein means the donepezil product contains an amount of impurity of formula (III) less than 0.1%, preferably less than 0.05% and more preferably less than 0.01%.
Donepezil obtained by following the process of the present invention may be further purified, for example, by crystallization using a solvent or mixture of solvents to obtain donepezil in high purity and high yield. Donepezil obtained as a free base may be further converted to pharmaceutically acceptable salts.
The process is safe, simple, and easy as compared to those processes disclosed in the prior art. In an embodiment, the process uses a solvent comprising a mixture of acetic acid, ethyl acetate, and rectified spirit and this makes the process industrially and commercially viable. Further, in a preferred embodiment, the product obtained by following the process of the present invention, has a purity of at least 99.8% and contains less than 0.01% of impurity of formula (III).
The present invention also provides a method of treating a disease state prevented, ameliorated or eliminated by the administration of a cholinesterase inhibitor in a patient in need of such treatment, which method comprises administering to the patient a therapeutically effective amount of donepezil, or a pharmaceutically acceptable salt thereof, prepared according to the present invention, substantially as hereinbefore described.
While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention.
EXAMPLES
The invention is explained in more detail in the following working example. The example, which illustrates the method of the present invention, has a purely illustrative character and does not limit the extent of the invention in any respect.
Example 1
A solution of 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide (20 kg) and ammonium acetate (2 kg) in ethyl acetate (450 lt) was charged into a hydrogenator. Then acetic acid (22 kg) and rectified spirit (100 lt) were added. A catalyst slurry (prepared separately by slurrying platinum on carbon (4 kg; 10% w/w) in water (6.6 lt) and acetic acid (78 kg)) was charged to the hydrogenator.
The reaction mass was hydrogenated by applying a hydrogen pressure of 55-60 psi at 25-30° C. and was maintained for 4 hours. After completion of the reaction, the reaction mass was filtered. The catalyst was washed with a mixture of rectified spirit (180 lt) and water (100 lt).
The combined clear filtrate was distilled off below 45° C. to remove solvents. The residue obtained was stirred with water (100 lt) and the pH of the reaction mass was adjusted to 7.5-8.0 using liquor ammonia at 25-30° C.
The solid was extracted with ethyl acetate (200 lt×3). The ethyl acetate layer was dried over sodium sulphate (10 kg) and distilled under reduced pressure below 45° C. To the residue, methanol (50 lt) was charged and distillation continued to remove traces of ethyl acetate below 45° C. To the residue, methanol (10 lt) was charged, the reaction mass cooled to 15-20° C. The pH of the reaction mass was adjusted to 2.0-2.5 using methanolic hydrochloric acid. To this solution, diisopropylether (80 lt) was added, the reaction mass chilled to 0-5° C. and the solids filtered.
The solid was purified by dissolving in a mixture of methanol (80 lt) and dichloromethane (25 lt) and precipitated by adding diisopropylether (150 lt) at 25-30° C., and stirred for 1 hour. The solid obtained was filtered and dried at 30-35° C. The solid was recrystallized from a mixture of methanol (15 lt) and diisopropylether (150 lt) to obtain donepezil hydrochloride.
Yield: −14.0 kg (75%) HPLC purity >99.5%
Example 2
A solution of 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium bromide (10 kg) and 1-allylpyridinium bromide (2.65 kg) in ethyl acetate (225 lt) were charged into a hydrogenator. Then acetic acid (11 kg) and rectified spirit (50 lt) were added. A catalyst slurry (prepared separately by slurrying platinum on carbon (2 kg; 10% w/w) in water (3.3 lt) and acetic acid (39 kg)) was charged to the hydrogenator.
The reaction mass was hydrogenated by applying hydrogen pressure of 55-60 psi at 25-30° C. and was maintained for 4 hours. After completion of the reaction, the reaction mass was filtered. The catalyst was washed with a mixture of rectified spirit (90 lt) and water (50 lt).
The combined clear filtrate was distilled off below 45° C. to remove solvents. The residue obtained was stirred with water (50 lt) and the pH of the reaction mass was adjusted to 7.5-8.0 using liquor ammonia at 25-30° C.
The solid was extracted with ethyl acetate (100 lt×3). The ethyl acetate layer was dried over sodium sulphate (5 kg) and distilled under reduced pressure below 45° C. To the residue, methanol (25 lt) was charged and distillation continued to remove traces of ethyl acetate below 45° C. To the residue, methanol (5 lt) was charged, the reaction mass was cooled to 15-20° C. The pH of the reaction mass was adjusted to 2.0-2.5 using methanolic hydrochloric acid. To this solution, diisopropylether (40 lt) was added, the reaction mass chilled to 0-5° C. and the solids filtered.
The solid was purified by dissolving in a mixture of methanol (40 lt) and dichloromethane (12.5 lt) and precipitated by adding diisopropylether (75 lt) at 25-30° C., and stirred for 1 hour. The solid obtained was filtered and dried at 30-35° C. The solid was recrystallized from a mixture of methanol (7.5 lt) and diisopropylether (75 lt) to obtain donepezil hydrochloride.
Yield: −7.1 kg (77.42%) HPLC purity >99.5%
It will be appreciated that the invention may be modified within the scope of the appended claims.
The purity and impurity figures given in this specification are provided on a weight % basis. | The present invention provides a process for preparing donepezil or a salt thereof, the process comprising reducing a 1-benzyl-4-[(5,6-dimethoxy-1-indanon-2-yl)methylene]pyridonium halide of formula II, wherein X is bromide or chloride, in the presence of an ionic compound, a solvent, a catalyst and a source of hydrogen, to form donepezil and optionally converting the donepezil to the salt thereof. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/014,513, filed Jun. 19, 2014, titled BIOMARKER DETECTION AND IDENTIFICATION SYSTEM AND APPARATUS.
FIELD OF THE DISCLOSURE
[0002] The disclosed invention relates to a biomarker detector used to detect and identify a biological substance. More specifically, the biomarker detector can be coated on a needle to enable a user of the coated needle to detect a bodily fluid when the needle is inserted into a patient.
BACKGROUND OF THE INVENTION
[0003] Efforts to improve surgical outcomes and cost structure, particularly with spinal surgery, have led to increased use of minimally invasive procedures. These procedures often use image-guided modalities such as fluoroscopy, CT, nerve stimulators, and, more recently, the Doppler ultrasound test. While often involving less risk than surgery, minimally invasive spinal procedures, pain management procedures, nerve blocks, ultrasound guided interventions, biopsy, and percutaneous placement or open intra-operative placement continue to carry risks of ineffective outcome and iatrogenic injuries, such as infection, stroke, paralysis and death due to penetration of various structures including, but not limited to, organs, soft tissues, vascular structures, and neural tissue such as, catastrophically, the spinal cord. Injuries can occur regardless of practitioner experience because a surgical instrument must proceed through several layers of bodily tissues and fluids to reach the desired space in the spinal canal.
[0004] To illustrate, the intrathecal (or subarachnoid) space of the spinal region, where many medications are administered, houses nerve roots and cerebrospinal fluid (CSF) and lays between two of the three membranes that envelope the central nervous system. The outermost membrane of the central nervous system is the dura mater, the second is the arachnoid mater, and the third, and innermost membrane, is the pia mater. The intrathecal space is in between the arachnoid mater and the pia mater. To get to this area, a surgical instrument must first get through skin layers, fat layers, the interspinal ligament, the ligamentum flavum, the epidural space, the dura mater, the subdural space, and the intrathecal space. Additionally, in the case of a needle used to administer medication, the entire needle opening must be within the sub-arachnoid space.
[0005] Because of the complexities involved in inserting a surgical instrument into the intrathecal space, penetration of the spinal cord and neural tissue is a known complication of minimally invasive spine procedures and spine surgery. Additionally, some procedures require the use of larger surgical instruments. For example, spinal cord stimulation, a form of minimally invasive spinal procedure wherein small wire leads are inserted in the spinal epidural space, requires that a 14-gauge needle be introduced into the epidural space in order to thread the stimulator lead. Needles of this gauge are technically more difficult to control, posing a higher risk of morbidity. Complications can include dural tear, spinal fluid leak, epidural vein rupture with subsequent hematoma, and direct penetration of the spinal cord or nerves with resultant paralysis. These and other high-risk situations, such as spinal interventions and radiofrequency ablation, occur when a practitioner is unable to detect placement of the needle or surgical apparatus tip in critical anatomic structures.
[0006] At present, detection of such structures is operator dependent, wherein operators utilize tactile feel, contrast agents, anatomical landmark palpation and visualization under image-guided modalities. The safety of patients is reliant upon the training and experience of the practitioner in tactile feel and interpretation of the imagery. Even though additional training and experience may help a practitioner, iatrogenic injury can occur independently of practitioner experience and skill because of anatomic variability, which can arise naturally or from repeat procedures in the form of scar tissue. Fellowship training in some procedures, such as radiofrequency ablation, is not sufficiently rigorous to ensure competence; even with training, outcomes from the procedure are considerably variable. In the case of epidural injections and spinal surgery, variability in the thickness of the ligamentum flavum, width of the epidural space, dural ectasia, epidural lipomatosis, dural septum, and scar tissue all add challenges to traditional verification methods even for highly experienced operators. Additionally, repeat radiofrequency procedures done when nerves regenerate, often a year or more later, are often less effective and more difficult because the nerves' distribution after regeneration creates additional anatomic variability.
[0007] No device exists that provides objective, reliable, consistent, real-time feedback of critical tissues and bodily fluids. Further, even the concept of objective device feedback has not been accepted by proceduralists, even though millions of spinal procedures are performed annually as standard of care throughout the world.
SUMMARY OF THE INVENTION
[0008] Disclosed is a biomarker detector that can both detect and identify at least one biological substance, such as bodily fluid or tissue. In some embodiments, the biomarker detector can detect two or more biological substances and accurately indicate which biological substance is being detected. The detector, operable by a person or a machine, can be used on humans or animals and is capable of continuous or intermittent detection. For example, a needle and stylet coated with a biomarker detector coating are able to detect, in real procedural time, bodily fluids, including, but not limited to, blood, cerebrospinal fluid, and nerve tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates an example of the disclosed invention in use.
[0010] FIG. 2 illustrates an example of the disclosed invention in use.
[0011] FIG. 3 illustrates an example of the disclosed invention.
[0012] FIG. 4A illustrates an example of the disclosed invention.
[0013] FIG. 4B illustrates an example of the disclosed invention.
[0014] FIG. 5 illustrates an example of the disclosed invention.
[0015] FIG. 6 illustrates an example of the disclosed invention.
[0016] FIG. 7 shows example needles currently used for a spinal procedure.
[0017] FIG. 8 shows an example of a needle currently used for a spinal procedure.
DETAILED DESCRIPTION
[0018] The present disclosure relates to a biomarker detector that is used to detect biological substances, such as bodily fluids and tissues. Various embodiments of the biomarker detector will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the biomarker detector disclosed herein. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the biomarker detector. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover applications or embodiments without departing from the spirit or scope of the disclosure. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.
[0019] In one embodiment, the biomarker detector is a coating placed on a procedural or treatment instrument or apparatus, such as, but not limited to, a needle, scalpel, BOVIE® device, pacemaker, electrode, intravascular catheter, intraluminal catheter, port, sheath, and implantable pump. FIG. 3 illustrates a stylet 302 inside a coated indicator 304 coated with the biomarker detector coating, wherein the indicator 306 is visible to an operator. FIGS. 4A and 4B illustrate a coated needle and stylet, wherein FIG. 4A shows a needle with a removable diaphragm cover 402 that covers the indicator 404 and an exposed cutting surface of the needle 406 , and FIG. 4B shows the needle with diaphragm cover removed and the indicator 404 exposed.
[0020] In one embodiment, a medical instrument has a biomarker detector coating on all, some, or just the tip of the medical instrument that is either continuously or intermittently exposed pending the application. The biomarker detector can indicate detection of a biological substance by conveying a confirmatory signal such as, but not limited to, a visual or audio signal.
[0021] In one embodiment, the coating on a needle has a chemically-sensitive surface. The surface can be sensitive to various bodily fluids and tissues. It can react to those fluids and tissues similar to how litmus paper reacts to different pH levels.
[0022] For example, a needle with the biomarker detector coating can be used in conjunction with ultrasound, wherein the color of the needle or separate device may change depending on the fluid or tissue. For example, the needle or separate device may be visible on an MRI and, as it gets closer to the spine, it may darken. This can occur because the interaction between the coating and the fluids and tissues it touches can cause different types or intensities of reactions. It can react to give a darker color with fluids and tissues closer to the spine and react to give a lighter color with fluids and tissues further from the spine, or vice versa. Therefore, a needle or separate device in contact with the epidural space will appear lighter on an MRI scan than one in contact with the intrathecal space. The signal can be sent from the penetrated aspect of the apparatus, through a lumen, channel, conduit, electric conduction, or coating to the unexposed aspect of the apparatus.
[0023] In another embodiment, the biomarker detector could be a separate device that is sent with the needle. In some embodiment, it can be attached to the outer surface of the needle. In another embodiment, it can be carried inside of a catheter and exposed to fluids and tissues upon action of a user. In yet a further embodiment, it can be a separate component that is not attached to the needle, but is guided by it.
[0024] In one embodiment, the coating on a needle or separate device conveys a confirmatory signal of only one type of bodily fluid or tissue. Therefore, different coatings would be used depending on the region of the spine a user wanted to identify. For example, if the user wanted access to the intrathecal space, the user would need a coating that would only signal upon reaching the intrathecal space and would not signal when it proceeds through the outer, epidural space.
[0025] In another embodiment, the same coating on a needle or separate device can convey a confirmatory signal for various types of bodily fluids or tissues the needle or separate device is interacting with. For example, the needle or separate device, if equipped with audio signal capabilities such as a beep, can give an audible signal when it interacts with various bodily fluids and tissues. To differentiate between the varying tissues and fluids, it can give beeps with shorter intervals if it is exposed to bodily fluids and tissues closer to the spine. Therefore, the length of time between beeps when the epidural space is reached will be longer than the length of time between beeps when the intrathecal space is reached. In another example, the coated needle or separate device can have a light-producing mechanism that is activated when the coating reacts to a specific type of tissue or fluid.
[0026] In another embodiment, the coating on the needle or separate device may have a coating that detects many types of tissues and fluids by the way the tissue or fluid reacts to light. For example, the needle or separate device, with a coating or a coated tip, can have a light-producing mechanism that the coated tip reacts to or reads. The light producing mechanism can be activated upon the user's initiation and can be a light given off by a flashlight on the needle itself or it can be a separate, secondary piece of equipment that is inserted into a body in a coordinated location. The tip can react to, or read, the light as it bounces off of surrounding fluids or tissues. Depending on the wavelength of the light as it bounces off of the tissue or fluid and to the coated tip, the detector can determine what type of tissue or fluid it is in contact with or in proximity to. Upon detection of the light, the tip can electronically send the reading to a computing and display system for the user to read. The computing and display system can be a separate device or it can be contained within the needle itself.
[0027] Similarly, in another embodiment, a needle or separate device can put off sound waves that bounce off of surrounding structures. Based on the type of surrounding tissue or fluid, the sound wave profile will change, and the detector can identify, based on the wave profile, the nature of the surrounding tissue or fluid. As the needle or separate device progresses through various tissues and fluids, the profile of the sound waves will change. A computing system can match the sound waves' profile to an existing profile coordinated with a specific tissue or fluid and can indicate to the user what the tissue or fluid is.
[0028] Detection of the desired tissue or fluid can occur with minimal to no interruption to the operator, which greatly enhances the safety profile of an extensive variety of medical procedures routinely performed with these instruments and other devices. The detector can be used for minimally invasive spinal procedures as well as in multiple other medical disciplines.
[0029] The detector may confer a therapeutic benefit by verifying one or more bodily fluids and tissue types to aid in the reduction of iatrogenic injury and more precise placement. For example, when a practitioner is conducting a procedure, such as an interlaminar injection, on a patient's spine, an instrument, such as a needle, will traverse through the CSF 102 before reaching the spinal cord 104 , as illustrated in FIG. 1 . If the CSF 102 can be detected via the needle and stylet instrument, or catheter with obturator instrument, when either instrument is coated with the biomarker detector coating and the biomarker detector coating can provide notification of this detection, the notification may help reduce iatrogenic injury by informing the practitioner that he or she is getting close to the spinal cord. FIGS. 7 and 8 illustrate typical needles used for injection into or near the spine that can be coated with the biomarker detector coating.
[0030] The biomarker detector can serve as a protective warning system, informing the surgeon, proceduralist, or machine of the real time location of the instrument by indicating the presence of a specific biological substance using an indicator system. The indicator system can alert the practitioner if the instrument contacts CSF, blood, a nerve, or other tissue when the instrument is used for a transforaminal injection, as illustrated in FIG. 2 . This alert adds a margin of safety for patients and providers alike. Regardless of whether the biological substance is bone, blood, nerve, cartilage, ligament, malignancy, or an organ, the apparatus's feedback facilitates precision in placement and increased safety. FIG. 5 illustrates one embodiment of the disclosed device wherein a stylet 502 acts as an indicator. FIG. 6 illustrates one embodiment of the disclosed device wherein an indicator 602 is on a removable diaphragm, or, alternatively, the diaphragm protects the indicator 602 until the user desires confirmation.
[0031] In one embodiment, the detection system is a robotic or other automated system that is monitored by a person. In another embodiment, the detection system is human-operated and involves no machines in the operation of the device. In some embodiments, the signal, whether auditory or visual, can be a relative or absolute signal. For example, the signal can provide absolute values of measurements taken of the type of fluid or tissue the coating is surrounded by. Alternatively, it can indicate values that are different, such as greater or smaller, than prior values when the coating moves from one type of fluid or tissue to another type.
[0032] Intentional spinal vascular access for stem cell and medication therapy has never before been pursued. Additionally, for decades, injections while on anti-coagulation were an absolute contraindication. New evidence exists that supports the idea that remaining on anticoagulation has a low risk of complication and offers protection from thrombosis. This evidence opens the door to intentional spinal vascular access for these therapies. Currently, the use of anticoagulation during lumbar transforaminal epidural steroid injections is performed on a case-by-case basis, depending on the unique risks of each patient. Fortunately, in the event of inadvertent injection of steroid into the spinal vasculature, remaining on anti-coagulation lowers the risk of spinal arterial occlusion. Dexamethasone, a non-aggregating, non-particulate steroid with a diameter of 0.5 micrometers, is exponentially smaller than red blood cells and also lowers the probability of spinal arterial occlusion. The disclosed invention could aid in further progressing intentional spinal vascular injections.
[0033] Given the concern of spinal arterial occlusion and the potential catastrophic side effects of paralysis, direct spinal radicular artery injection of steroids remains taboo, and is not pursued intentionally, even though intrathecal administration of steroids has been pursued, with significant therapeutic effect, for profoundly painful conditions such as post-herpetic neuralgia. Further, intrathecal opiate administration is accepted. Opiates, like steroids, have lipophilic characteristics, which vary from substance to substance. The relative potency of opiates as an analgesic for spinal pain increases exponentially the closer it is administered to the spinal cord. Oral, epidural, and intrathecal dosing vary in analgesic potency by factors of 1, 10 and 100, respectively. Therefore, extrapolating this trend to the spinal vasculature offers a potency factor of 1000 times higher than oral administration. Additionally, vascular uptake seen in interventional spinal procedures, while technically a reason to terminate the procedure, is pursued with dexamethasone given its safety profile with profound analgesic effect.
[0034] Direct administration of pharmacologic agents into the spinal circulation while the patient is anti-coagulated would offer a new generation of analgesia given new evidence (a) that remaining on anti-coagulation for epidural steroid injections is permissible, (b) that dexamethasone is shown not to occlude arterial circulation, and (c) that the relative potency of lipophilic medications increases exponentially the closer it comes into contact with the spinal cord. The 1000 times higher potency afforded by direct spinal arterial injection can allow microscopic amounts of medication to be introduced.
[0035] Using microscopic amounts of medication has several benefits. For decades, oral and intravenous steroids have been administered to acute spinal cord injury patients to reduce the secondary cascade of pathophysiologic mechanisms, which include inflammatory response, ischemia, lipid peroxidation, apoptosis, fluid and electrolyte disturbances, and production of free radicals, which produce a glial scar, a barrier to regeneration. Yet, their potency is exponentially lower, with greater side effects such as infection risk due to immunosuppression in the pediatric population compared to epidural, intrathecal, or radicular artery administration. Direct spinal arterial injection could allow less medication to be used and result in higher efficacy as well as fewer side effects.
[0036] While spinal interventions, injections, and surgery have many associated risks, confirmation of nerve and bone tissue using the disclosed biomarker detector offers improved efficacy for these scenarios. Being able to differentiate lumbar disc annulus fibrosis and nucleus pulposis tissue can increase the precision of lumbar discography, lumbar percutaneous disc decompression, and intradiscal stem cell therapy.
[0037] Detection of various tissue and fluid types in contact with the coated needle and stylet lowers the probability of catastrophic complication by informing the provider and or machine when critical structures, including blood and CSF, have been contacted by the needle, allowing the provider to have real time feedback, and give pause before further advancing the needle. Identical safety advantages apply in cervical and thoracic interlaminar epidural steroid injections, epidural anesthesia and catheter placement and spinal taps.
[0038] Many medical conditions can benefit from this new technology. For example, the implications for diseases with inflammation of, or trauma to, the spinal cord given this new technology are profound. Administration of at least epidural, if not intrathecal or spinal radicular artery steroid, has substantial potential to reduce secondary pathology due to spinal cord injury.
[0039] Additionally, patients suffering from degenerative neurologic conditions of the central nervous system, including multiple sclerosis, in acute flairs, similarly are grounds for study, as the degree of potency of spinal steroid administration has the capacity to arrest flairs and decelerate the pace of relapsing remitting disease. Intra-spinal administration of anti-inflammatory agents offers reduced side effect profile, opportunity for greater compliance, and again, the capacity to arrest acute flairs.
[0040] Further, patients suffering from mental illness who have difficulty with compliance of medication may benefit from epidural injection of relevant medication due to increased potency of spinal administration. Epidural injection also minimizes systemic side effects. Particularly in severe, acute cases, various psychotropic agents at oral doses can have undesirable side effects, such as extrapyramidal features, which lower compliance. Spinal administration can minimize systemic side effects of agents such as lithium, thorazine and haloperidol, as relative microdosing can be used to treat the symptoms.
[0041] Lastly, while the introduction of stem cells into the spinal canal can presently be performed, it requires surgery, which induces scar tissue and requires millions of cells to induce a graft. Spinal administration would be less invasive, could increase specificity of update into ischemic regions of the spinal cord, and therefore, could be more effective and have fewer risks. With a complete cord injury, introduction of stem cells below the level of spinal cord injury via the radicular artery carries little risk since trauma at the more proximal level has already occurred. The artery of Adamkiewicz is a narrow 1.2 mm diameter target, but affords direct vascular access to the spinal cord. The S1 vertebral foramen, at 21.3% and existing bilaterally, has nearly double the rate of incidental vascular penetration as other areas in lumbar spine. In one embodiment, a needle and stylet, or micro catheter with obturator, can identify a radicular artery and increase the probability of vascular penetration. Using the disclosed technology, as well as a Doppler ultrasound test, a practitioner can consistently reach this or another arterial target to deliver steroids, stem cells, or micro concentration of analgesics or medications. With a minimal diameter of 230 microns, the anterior spinal artery offers sufficient diameter to accommodate direct vascular injection, which, as described above, can increase specificity of uptake into ischemic regions of the spinal cord.
[0042] Needles and stylets, and catheters with obturators, that can detect biological substances, including nervous tissue and arterial circulation, could facilitate intentional radicular arterial access, allowing the interventionalist to place steroid, stem cells, medications, nano probes or other analgesic agents directly into the spinal circulation. This is dependent upon the interventionalist, or machine, being able to directly deliver the substance to the spinal circulation at the level of injury. The capacity of the device to detect nervous structures and vascular structures facilitates spinal vascular access. For more conventional procedures, simple detection of the vascular structure eliminates unintended vascular administration of medication, reducing the probability of catastrophic side effects.
[0043] The disclosed technology can reduce catastrophic complications associated with spinal procedures, reduce the severity of spinal cord injury associated with spinal procedures, offer new treatments for degenerative CNS conditions such as Multiple Sclerosis, and increase analgesic effect. Additionally, this alert system may enable mechanized surgical systems to accurately perform spinal procedures. | A biomarker detector used to detect and notify a user of a biological substance. More specifically, a biomarker detector coating layered on a surgical instrument that enables a user of the surgical instrument to know when a critical bodily fluid, such as cerebrospinal fluid, or critical tissue, such as nerve tissue, has been reached by the surgical instrument, thereby allowing the user to react accordingly and avoid iatrogenic injury. | 0 |
This is a division of patent application Ser. No. 08/775,072, filing date Dec. 27, 1996, now U.S. Pat. No. 5,721,166 Method To Increase The Resistance Of A Polysilicon Load Resistor, In An Sram Cell, assigned to the same assignee as the present invention.
BACKGROUND OF THE INVENTION
(1) FIELD OF THE INVENTION
The present invention relates to a method of fabricating metal oxide semiconductor, (MOSFET), devices, on a semiconductor substrate, for use in a static random access memory, (SRAM), cell, and more specifically to a process used to form polysilicon load resistors, for the SRAM cell, using doping procedures and topography to enhance the resistance of the polysilicon load resistor.
(2) DESCRIPTION OF THE PRIOR ART
Static random access memory, (SRAM), cells are now being manufactured using high speed, high density, MOSFET devices. Conventional SRAM cells are usually configured using either four, n-channel, and two, p-channel, MOSFET devices, or via use of four, n-channel, MOSFET devices, with two load resistors, used in place of the p-channel devices. The use of the load resistors, in place of the p-channel MOSFET devices, consumes less area then the complimentary MOSFET counterparts, and therefore has found extensive use in advanced SRAM designs. A triple polysilicon process has frequently been used to accommodate the load resistor option for SRAM cells. In this process a first polysilicon layer is used for the gate structure of the MOSFET device, while a second polysilicon layer is used as a local interconnect, as well as a contact structure to a source and drain region of an underlying n-channel MOSFET device. A third polysilicon layer is used for creation of the load resistors. In order to enhance or increase the resistance of the polysilicon device, which is needed for many SRAM designs, the doping level of the polysilicon layer has to be decreased, or the length of the load resistor has to be increased. Difficulties in controlling lower dopant levels in polysilicon layers, do not allow low doped, polysilicon load resistors, to be easily fabricated. In addition the option of increasing the length of the polysilicon load resistor is limited by the finite dimensions presented in advanced SRAM designs.
This invention will present a process in which the resistance of polysilicon load resistors can be increased, without consuming additional area, and without the use of a less controllable, low doping procedure. This invention will show the use of underlying topography, resulting from an underlying grid pattern, allowing the load resistor to traverse this topography, thus increasing length and resistance of the load resistor. In addition doping of the polysilicon layer is performed to create back to back diodes, in the polysilicon load resistor, again resulting in a higher load resistance then counterparts fabricated without the back to back diode procedure. Prior art, such as Sweeny, in U.S. Pat, No. 5,424,239, shows a method of forming polysilicon resistors with alternating doped and undoped regions, however that invention does not teach the process of lengthening the resistor via an underlying topography, nor does it show a process for achieving back to back diodes, again via the use of the severe underlying topography.
SUMMARY OF THE INVENTION
It is an object of this invention to fabricate MOSFET devices, for an SRAM cell, in which a polysilicon load resistor is created, in an area of the MOSFET device, overlying the transfer gate transistor of the MOSFET device.
It is another object of this invention, to create a grid pattern in an underlying local interconnect level, resulting in a raised grid topography.
It is still another object of this invention to increase the length, and therefore the resistance, of a polysilicon load resistor, by allowing the polysilicon load resistor to traverse the underlying raised grid topography.
It is still yet another object of this invention to form back to back diodes in a polysilicon load resistor, via the use of a blanket ion implantation process, resulting in the doping of only the flat portions of the polysilicon load resistor, while portions of the polysilicon load resistor, on the sides of the raised grid topography, remain undoped.
In accordance with the present invention a method is described in which the resistance of a polysilicon load resistor, used with MOSFET devices, for SRAM cells, is increased via increasing the length of the resistor, by forming the resistor on an underlying raised grid pattern, and by forming back to back diodes in the polysilicon load resistor. A transfer gate transistor, for a MOSFET device, is created by: forming a polysilicon gate structure, from a first polysilicon layer, on an underlying gate insulator layer; forming a lightly doped source and drain region in the semiconductor substrate, not covered by the polysilicon gate structure; forming an insulator spacer on the sides of the polysilicon gate structure; and creating heavily doped source and drain regions, in the region of the semiconductor substrate not covered by the polysilicon gate structure or insulator spacers. A first interlevel dielectric layer is deposited, and a contact hole is opened in the first interlevel dielectric layer, to expose a heavily doped region, between polysilicon gate structures. A second polysilicon layer is deposited and patterned, using photolithographic and reactive ion etching, (RIE), procedures, to create: a local interconnect level, including the contact structure to the underlying heavily doped source and drain region; and a series of polysilicon mesas, on the underlying first interlevel dielectric layer, created to result in a raised grid topography, on the underlying first interlevel dielectric layer. A second dielectric layer is deposited on the underlying, raised grid topography, followed by the deposition of a third polysilicon layer, grown using a P type, in situ doping procedure, or grown intrinsically and doped P type, and traversing the underlying, raised grid topography. Photolithographic and RIE procedures are then used to pattern the third polysilicon layer. A heavily doped, N+, ion implantation is performed, in regions of the third polysilicon layer to be used for contact areas to the subsequent polysilicon load resistor. A blanket, N type, ion implantation procedure, is then performed, creating N type regions in the flat regions of the third polysilicon layer, while regions of third polysilicon layer, located on the sides of the raised grid topography, do not experience the N type ion implantation procedure, and remain P type. The polysilicon load resistors, with the desired polysilicon resistor lengths, now exhibit resistances increased as a result of traversing the underlying, raised grid topography, and resistance also increased as a result of back to back diode formation.
BRIEF DESCRIPTION OF THE DRAWINGS
The object and other advantages of this invention are best described in the preferred embodiment with reference to the attached drawings that include:
FIGS. 1-7, which schematically in cross-sectional style, present the key fabrication stages of the polysilicon load resistor, overlying a MOSFET device, and used for an SRAM cell, in which the resistance of polysilicon load resistor is increased as a result of the polysilicon load resistor traversing an underlying, raised grid topography, as well as the use of back to back diodes in the polysilicon load transistor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method of fabricating a polysilicon load resistor, overlying a MOSFET device, used for an SRAM cell, in which the resistance of the polysilicon load resistor is increased by increasing the length of the resistor, by formation of the resistor on an underlying, raised grid topography, as well as increasing the resistance of the polysilicon load resistor by forming back to back diodes in the polysilicon load resistor, will be described.
FIG. 1, schematically shows the transfer gate transistor used for the MOSFET device, which underlies the enhanced polysilicon load resistors, described in this invention. This embodiment uses an n-channel, MOSFET device, however if desired a p-channel, MOSFET device, can also used with this invention, by simply changing conductivity type for source and drain regions. A P type, single crystalline, silicon substrate, 1, with a <100> crystallographic orientation, is used. Field oxide, (FOX), regions, 2, are used for purposes of isolation. FOX regions, 2, are formed to a thickness between about 3000 to 5000 Angstroms, via thermal oxidation of exposed regions of silicon substrate, 1, in an oxygen-steam ambient, at a temperature between about 850 to 1050° C. Non-oxidized regions, of silicon substrate, 1, are protected by a composite oxidation mask of silicon nitride-silicon oxide, created by forming the desired pattern in the chemically vapor deposited silicon nitride-silicon oxide layers, using conventional photolithographic and RIE procedures. After formation of the FOX regions, 2, the composite oxidation mask, silicon nitride-silicon oxide, is removed and a gate insulator layer, of silicon dioxide, 3, is thermally grown in an oxygen-steam ambient, at a temperature between about 850 to 1000° C., to a thickness between about 50 to 200 Angstroms. A first layer of polysilicon, 4, is next deposited using low pressure chemical vapor deposition, (LPCVD), procedures, at a temperature between about 500 to 700° C., to a thickness between about 1500 to 3500 Angstroms. Polysilicon layer, 4, can be grown intrinsically and doped via ion implantation procedures, using arsenic or phosphorous, at an energy between about 30 to 75 KeV, at a dose between about 1E14 to 1E16 atoms/cm 2 , or polysilicon layer, 4, can be deposited using in situ doping procedures by adding either phosphine or arsine, to the silane ambient. A silicon oxide layer, 5, is next deposited, using either LPCVD or plasma enhanced chemical vapor deposition, (PECVD), procedures, at a temperature between about 500 to 700° C., to a thickness between about 1000 to 3000 Angstroms, using tetraethylorthosilicate, (TEOS), as a source. Conventional photolithographic and RIE procedures, using CHF 3 as an etchant for silicon oxide layer, 5, and Cl 2 as an etchant for polysilicon layer, 4, are used to create polysilicon gate structures, comprised of silicon oxide layer, 5, and polysilicon layer, 4, shown schematically in FIG. 1.
After removal of the photoresist shape, used for patterning the polysilicon gate structures, via plasma oxygen ashing and careful wet cleans, a lightly doped source and drain region, 6, is created via ion implantation of either phosphorous or arsenic, at an energy between about 25 to 75 KeV, at a dose between about 5E13 to 5E13 atoms/cm 2 . Another silicon oxide layer is then deposited, using LPCVD or PECVD procedures, at a temperature between about 500 to 700° C., to a thickness between about 1500 to 3000 Angstroms, using TEOS as a source, followed by an anisotropic RIE procedure, using CHF 3 as an etchant, to create silicon oxide spacers, 7, on the sides of the polysilicon gate structures, shown schematically in FIG. 1. Heavily doped source and drain regions, 8, are next created visa ion implantation of either arsenic or phosphorous, at an energy between about 50 to 100 KeV, at a dose between about 1E14 to 1E16 atoms/cm 2 . A first interlevel dielectric layer, 9, of silicon oxide, is deposited using LPCVD or PECVD procedures, at a temperature between about 500 to 700° C., to a thickness between about 3000 to 7000 Angstroms, using TEOS a source. Photolithographic and RIE procedures, using CHF 3 as an etchant, are used to open contact hole, 10, in the first interlevel dielectric layer, 9, exposing heavily doped source and drain region, 8, located between polysilicon gate structures, and schematically shown in FIG. 1. Photoresist removal is again performed using plasma oxygen ashing and careful wet cleans.
A second layer of polysilicon, 11a, shown schematically in FIG. 2, is next deposited, again via LPCVD procedures, at a temperature between 500 to 700° C., to a thickness between about 300 to 3000 Angstroms. Polysilicon layer, 11a , can either be deposited intrinsically, and doped via ion implantation of phosphorous or arsenic, at an energy between about 25 to 50 KeV, at a dose between about 1E13 to 1E15 atoms/cm 2 , or polysilicon layer, 11a, can be deposited using in situ doping procedures, by the addition of either phosphine or arsine, to the silane ambient. Photoresist shape, 12b, is then formed to be used as a mask to define subsequent interconnect polysilicon levels, and to define a subsequent polysilicon contact structure. Photoresist shapes, 12a, are also formed, to be used as a mask to define the subsequent polysilicon shapes, that will form a raised grid topography, consisting of polysilicon mesas. These photoresist shapes are schematically shown in FIG. 2. An anisotropic RIE procedure, using Cl 2 as an etchant, is next employed to etch second polysilicon layer, 11a, creating a local interconnect level, as well as polysilicon contact structure, 11b, contacting heavily doped source and drain region, 8, between polysilicon gate structures. The anisotropic RIE procedure also creates polysilicon mesas, 11a. The series of polysilicon mesas, 11a, located on the top surface of first interlevel dielectric layer, 9, result in a raised grid topography, with the level of topography resulting from the height of polysilicon mesas, 11a, or the thickness of the second polysilicon layer, between about 300 to 3000 Angstroms. The spacing between polysilicon mesas is between about 3000 to 8000 Angstroms. FIG. 3, schematically shows the defined polysilicon structures, after removal of photoresist shapes, 12a and 12b via, use of plasma oxygen ashing and careful wet cleans.
A second interlevel dielectric layer, 13, of silicon oxide, is deposited using either LPCVD or PECVD procedures, at a temperature between about 500 to 700° C., to a thickness between about 500 to 3000 Angstroms, using TEOS as a source. Second interlevel dielectric layer, 13, contours, and completely passivates the underlying polysilicon mesas, 11a, as well as polysilicon contact structure, 11b. This is schematically shown in FIG. 4. A critical, third polysilicon layer, 14a, to be used for the subsequent polysilicon load resistor, is next deposited at a temperature between about 500 to 700° C., to a thickness between about 300 to 600 Angstroms. Third polysilicon layer, 14a, which contours the underlying, raised grid topography, created by polysilicon mesas, 11a, can be deposited intrinsically, to a thickness between about 500 to 700 Angstroms, exhibiting P type characteristics, or third polysilicon layer, 14a, can be deposited via in situ doping procedures, by the addition of diborane to the silane ambient, to a thickness between about 300 to 600 Angstroms. The P type doping level of third polysilicon layer, 14a, between about 1E12 to 5E13 atoms/cm 2 , will be a factor in the formation of the back to back diodes, created in a subsequent polysilicon load resistor. Third polysilicon layer, 14a, is schematically shown in FIG. 4.
Photolithographic and RIE procedures, using Cl 2 as an etchant are used to define polysilicon load resistor, 15a, and polysilicon load resistor, 15b, schematically shown in FIG. 5, after photoresist removal using plasma oxygen ashing and careful wet cleans.
Regions of the subsequent polysilicon load resistor, to be used for contact purposes, are next addressed. Photoresist shapes, 20, are formed, and used as a mask to protect the P type portions of third polysilicon layer, 14a, from an ion implantation of either phosphorous or arsenic, at an energy between about 10 to 30 KeV, at a dose between about 1E14 to 5E15 atoms/cm 2 , used to create N+ regions, 14b, in the third polysilicon layer, 14a, shown schematically in FIG. 6. Photoresist shapes, 20, are then removed using plasma oxygen ashing and careful wet cleans.
The back to back diodes, in third polysilicon layer, 14a, are next created via a blanket ion implantation procedure, using arsenic or phosphorous, at an energy between about 10 to 30 KeV, at a dose between about 5E13 to 5E14 atoms/cm 2 , and at an implant angle between about 0 to 7°. This procedure converts the P type portions, only on the flat portions of third polysilicon layer, 14a, to an N type region, 14c. The ion implantation procedure is unable to convert the P type portions, of third polysilicon layer, 14a, to N type regions, 14c, in areas in which the third polysilicon layer is located on the sides of the raised grid topography, thus resulting in back to back diodes, of alternate, and connecting regions of N type, 14c, third polysilicon layer, and regions of P type, 14a, third polysilicon layer. This is schematically shown in FIG. 7.
Polysilicon load resistor, 15a, is comprised of back to back diode pairs, of N+-N-P-N-P-N-P-N-P-N-N+, (14b-14c-14a-14c-14a14c-14a-14c-14a-14c-14b). The resistance of polysilicon load resistor, 15a, has been increased as a result of the increased resistor length, obtained from polysilicon load resistor, 15a, traversing the raised grid topography. The resistance of polysilicon load resistor, 15a, has also been increased as a result of the inclusion of the back to back diodes pairs. Polysilicon resistor load, 15b, has been shown for this invention, to also experience resistance increases as a result of traversing the raised grid topography, and the inclusion of the dopants to form the diodes in the polysilicon load resistor. However the desired design, described in this invention, required a resistance for polysilicon load resistor, 15b, less then the desired resistance for polysilicon load resistor, 15a. Therefore the length of polysilicon load resistor, 15b, is shorter then counterpart, polysilicon load resistor, 15a, and with only one pair of back to back diodes.
While this invention has been particularly shown and described with reference to, the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of this invention. | A method for fabricating polysilicon load resistors, with increased resistance values, for use in SRAM cells, has been developed. An underlying, raised grid topography is used to allow the overlying polysilicon load resistor to traverse the severe topography, resulting in an increase in resistor length, while still maintaining the allotted design space, overlying a MOSFET device. The formation of back to back diodes in the polysilicon load resistor also results in an increase in resistance. The back to back diodes are created via N type, ion implantation into only flat regions of an intrinsic, or P type doped, polysilicon load resistor, regions in which the polysilicon load resistor overlaid the flat regions of the underlying raised grid topography, leaving regions of the polysilicon load resistor, located on the sides of the underlying raised grid topography, P type. | 8 |
REFERENCE TO RELATED PATENT APPLICATIONS
This application is a continuation-in-part of my co-pending patent application Ser. No. 712,888 filed Mar. 18, 1985, now U.S. Pat. No. 4,664,186.
BACKGROUND OF THE INVENTION
In my copending patent application Ser. No. 712,888 filed Mar. 18, 1985, now U.S. Pat. No. 4,664,186, there is set forth a downhole hydraulically actuated pump having a traveling engine valve and a traveling production valve, and a discharge guide assembly connected between the engine and production ends. This unique assembly provides a downhole hydraulically actuated pump having the maximum possible size engine piston and pump plunger. This is so because no external passageways are required in order to provide the engine end with power fluid and to provide the pump end with formation fluid.
The present invention provides improvements in traveling valves for a pump plunger. The improved traveling valve can be used in my above recited, copending patent application, as well as various other types of reciprocating pumps, as for example, the various different downhole pumps referred in this and my copending patent application.
The traveling valve assembly of the present invention is unique in that a connecting rod extends through the pump plunger and forms the valve element. The lower end of the connecting rod extension provides an inlet by which formation fluid is conducted to the production valve assembly. The production plunger provides another part of the valve assembly, and passageways are formed therein which lead to the upper and lower production chambers.
The connecting rod enlargement and production plunger therefore form a lost motion coupling therebetween which move respective to one another in order to open and close the passageways leading to the upper and lower production chambers of the production end. The valve is actuated in response to movement of the connecting rod. This involves inertia, friction, and fluid pressure effected on the valve element and the pump plunger.
SUMMARY OF THE INVENTION
The present invention provides improvements in traveling valves for a pump plunger. The improved traveling valve is a production valve assembly that can be used in various types of reciprocating pumps, as for example, the various different downhole pumps referred in this and my copending patent application. The traveling valve assembly of the present invention is unique in that a connecting rod extends through the pump plunger and is enlarged to provide a valve element. The lower end of the connecting rod that extends through the pump provides an inlet by which formation fluid is conducted from the lower end of the pump, through the lower pump chamber, and to the production valve assembly.
The production plunger provides another part of the valve assembly in the form of a valve chamber. The plunger has passageways formed therein which lead to the upper and lower production chambers, or working chambers.
The connecting rod enlargement and production plunger therefore cooperate together to form a lost motion coupling therebetween which move a limited amount respective to one another in order to open and close the passageways leading to the upper and lower production chambers of the production end. The valve is actuated in response to movement of the connecting rod. This involves inertia, friction, and fluid pressure effected on the valve element and the pump plunger.
A primary object of this invention is the provision of a traveling valve assembly for the production end of a production pump which has only two moving parts.
Another object of this invention is to provide a traveling production valve that is built into the production plunger that is actuated in response to inertia, pressure differential, and friction.
A further object of this invention is to disclose and provide a traveling valve assembly which is enclosed within a pump plunger and has a valve element which is an enlargement of a connection rod extension, and which includes a marginal end which continues downhole to a source of formation fluid.
These and various other objects and advantages of the invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings.
The above objects are attained in accordance with the present invention by the provision of a combination of elements which are fabricated in a manner substantially as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken, side elevational view of a downhole pump assembly made in accordance with the present invention;
FIG. 2 is an enlarged, fragmentary, longitudinal, part cross-sectional view illustrating some of the details of the pump disclosed in FIG. 1;
FIG. 3 is a longitudinal, part cross-sectional view of a modification of the pump seen in FIG. 2;
FIG. 4 is a further enlarged, fragmentary, longitudinal, part cross-sectional view of part of the apparatus disclosed in the foregoing figures;
FIG. 5 sets forth a modification of the apparatus disclosed in FIG. 4;
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is an enlarged, fragmentary, longitudinal, part cross-sectional view of part of the apparatus disclosed in FIGS. 1-3; and,
FIG. 8 is an enlarged, fragmentary, longitudinal, part cross-sectional view of another part of the downhole pump disclosed in FIGS. 1-3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figures of the drawings, and in particular FIG. 1, there is disclosed an improved downhole pump 10, many of the details being more fully set forth in my copending patent application Ser. No. 712,888 filed Mar. 18, 1985, now U.S. Pat. No. 4,664,186, of which this patent application is a continuation in part. The downhole pump 10 includes an upper end 11 opposed to a lower end 12. Production fluid flows into the nose or lower end 12 of the pump while hydraulic power fluid flows into the tubing 14 at the upper terminal end of the pump. An engine 15 is located uphole of a seal assembly 16. A grooved power fluid outlet section 17, the details of which are set forth in my above described patent application, exhausts spent power fluid from spent power fluid outlet ports 18.
A production pump assembly 20 is reciprocated by the engine end 15 and receives production fluid from the lower inlet end 12, and exhausts the produced fluid through production ports of outlet assembly 21 and 22.
The pump of FIG. 1 can be of the free or fixed type as illustrated in FIGS. 2 and 3. In FIG. 2, the downhole pump assembly 10 is provided with a seal assembly 16, 16' which is received in sealed relationship within a receptable 23 so that the spent power fluid which exits port 18 must flow into the illustrated annulus 23', into the spent power fluid return conduit 24, and uphole to the surface of the ground. The production fluid exiting ports 21 and 22 of the outlet assembly flows into annulus 25, downhole to ports 26, up the annulus 27, and to the surface of the ground. The annulus 27 is formed between casing 28 and the power fluid string 29.
Engine end 15 includes a cylinder having a piston 30 which has a valve therein, made in accordance with my previous U.S. Pat. Nos. 3,517,741 issued June 30, 1970 and 3,627,048 issued Dec. 14, 1971. Therefore, the engine piston 30 is said to have a traveling valve associated therewith. The traveling valve receives power fluid from the hollow inlet rod 14 which communicates with the traveling valve assembly "V" of piston 30 and reciprocates therewith. A piston rod 31 is axially aligned with the power fluid inlet rod 14. The piston rod 31 extends axially down through the pump assembly, almost to the lower end thereof where the open end of the rod receives formation fluid, as will be more fully explained later on.
Piston 30 divides the engine 15 into an upper power chamber 32 and a lower power chamber 33. There are seal assemblies at the opposed ends of the upper and lower chambers for isolating the chambers so that fluid flows to and from the chambers only through the traveling valve "V".
The discharge section 17 includes the illustrated slide discharge element 34 which divides chamber 17 into an upper chamber 35 and a lower chamber 36. The slide 34 includes the illustrated ports therein which are connected to the interior of the hollow connecting rod 31 and communicates with the valve "V" of engine piston 30.
The production end of the pump assembly includes a production outlet valve and seal assembly schematically illustrated at 21 and 22; which define a production chamber within which a production piston 37, made in accordance with this invention, is reciprocatingly received. The novel production piston 37 of the present invention includes the illustrated valve means contained therewithin by which formation fluid is received through the lower hollow connecting rod, as will be more fully explained later on. The upper and lower production pump seal and outlet assembly 21, 22 exhaust produced fluid into the annulus 25. The annulus 25 is formed between the pump barrel and the oil supply string 29 so that the produced fluid is forced to flow downhole toward produced fluid outlet port 26, and then back up through the annulus 27 and to the surface of the ground. Accordingly, the pump system disclosed in FIG. 2 is of the type that maintains the power oil in a closed system which is separate from the produced fluid.
In the system set forth in FIG. 3, power fluid is pumped down the power oil string and enters the power oil inlet 14 as in the before described manner, and thereby reciprocates the engine piston 30 as the traveling valve causes the power oil to alternately flow into the upper and lower power chambers. Spent power fluid is alternately exhausted from the power oil chambers and flows from the valve, down through the connecting rod 31, to the guide device 34 where the oil is exhausted through the guide ports and into chamber 35, and then flows back up through the annulus to the outlet 18, and into the annulus 25 formed between the pump and the power oil string 29.
At the same time, formation fluid below the packer B enters the lower end of the pump, and flows into the lower connecting rod extension at inlet 40. Sleeve 41 sealingly and slidably receives the lower marginal end of the rod extension 31" in a reciprocating manner.
As the production piston 37 reciprocates within the pump barrel, formation fluid flows through the pump piston traveling valve and into alternate ones of the chambers 38, 39, while the produced fluid is alternately exhausted from the production chambers by means of the seal and outlet assembly 21 and 22, the details are set forth in FIG. 7.
Accordingly, spent power fluid from port 18 and produced fluid from the production check valves 21 and 22 of the seal and outlet assembly comingle within the annulus 25 and exit the power oil string annulus at ports 26 where the mixed fluid flows uphole through casing annulus 27.
FIGS. 4-6 of the drawings illustrate the details of alternant embodiments of the production piston 37 which were diagrammatically disclosed in the foregoing figures. As seen in the first embodiment of FIG. 4, the production piston 37 is reciprocated by connecting rod 31' in response to reciprocation of the engine piston 30 of FIGS. 2 and 3. The rod 31' of FIGS. 4 and 5 interconnecting the engine piston and the adjacent production piston is solid up to the guide members 34, (FIG. 3) where the rod must then be hollow so that the sliding guide member 34 can receive spent power fluid from the valve of piston 30.
FIG. 7 shows an outlet production valve assembly which can be used for controlling the flow of produced fluid from chambers 38 and 39 of either of the embodiments of the invention set forth in FIGS. 4 and 5. The details of FIG. 7 are more fully set forth later on herein.
Where a double production end is desired, the connecting rod 31 of FIG. 7 must be made hollow between the two production pistons as indicated by the numerals 37 and 137 in order to also provide formation fluid to the second production piston 137 (not shown). An outlet passageway 70' would also be required so that produced fluid from the adjacent production chamber can be exhausted through port 21 of the outlet assembly, for example. The double production ends would be placed one above the other with formation fluid being supplied to both production ends by means of the hollow rod 31.
In FIGS. 4-7, outer pump housing 44 forms upper and lower working chambers 38 and 39, with formation fluid entering a formation fluid chamber 45 by means of the internal passageway 40' formed within the lower connecting rod extension 31". As the plunger, or piston 37, stroks upward, the fluid in the upper production chamber 38 is exhausted through the upper check valve means 21 (FIGS. 2 and 3), the details of which are more fully disclosed in FIG. 7. At the same time, formation fluid enters the lower end 12 (FIG. 2) of the pump, and flows into the lower end 40 of the connecting rod extension 31", then flows through passageway 40', into chamber 45, and then through the seat 48 and the lower ball check valves 49', spring 50', and production piston passageway 51', thereby filling the lower production cylinder chamber 39 with formation fluid. The lower exhaust valve 22 (FIG. 2) is constructed identical to the exhaust valve 21 and the two valves 21 and 22 are arranged in confronting relationship respective to the opposed ends of the piston in the illustrated manner of FIG. 7.
In FIGS. 5 and 6, there is set forth a novel improvement of the production end 20 of the pump 10 disclosed in the foregoing figures. The improvement comprises an alternate embodiment of the combination valve and production piston 37 previously seen in FIGS. 1-4. The combination traveling valve 52 and plunger 137 includes a unitary valve element which is contained within a unitary production plunger, and as seen illustrated in FIGS. 5 and 6, the cylindrical sliding valve element 52 is connected within the connecting rod 31' and hollow rod extension 31". The connecting rod at 31' can be made solid where only one production piston or plunger 137 is employed in the production end. The valve element 52 includes a cylindrical outer body surface 53 having lateral ports 54 extending radially from the central passageway 40' thereof.
A cylindrical chamber 55 is formed axially within hollow plunger 137 and slidably receives the valve element 52 in a reciprocating manner in close tolerance relationship therewithin. The chamber 55 is of a length to slidably receive the valve element 52 in captured relationship therewithin as seen illustrated in FIG. 5. The valve element 52 and plunger 137 are advantageously used for controlling fluid flow from formation fluid passageway 40' alternately to the opposed production chambers 38 and 39.
Numeral 56 indicates the inside peripheral wall surface of the chamber 55. Lateral ports 57 and 58, respectively, are connected to chambers 38 and 39, respectively, by means of separate longitudinal passageways 151, 151, respectively. Chamber 55 includes opposed annular shoulders 59 and 60 formed at opposed ends thereof for abuttingly engaging the coacting opposed shoulders 61 and 62 formed at opposite ends of the valve element 52.
Hence, shoulders 60, 62 and 59, 61 form stop means to limit the relative axial motion between the plunger and valve element each stroke that the engine imparts into the connecting rod. The ports 57, 58 are spaced axially from one another a distance equal to the maximum spacing of annular shoulders 59 and 61 or 60 and 62 when the valve element 52 is stroked by the engine so that as the valve element 52 abuttingly engages either of the plunger shoulders 59 and 60, one of the ports, 57 or 58, are aligned with one of the valve element ports 54. Accordingly, as the engine downstrokes connecting rod 31', the plunger and valve assembly assume the configuration set forth in FIGS. 5 and 6; and, when the engine upstrokes the rod 31', the production plunger and valve assembly assume that alternate configuration wherein shoulders 59 and 61 abuttingly engage one another and ports 54 and 57 are brought into alignment with one another.
In FIG. 7, there is disclosed the details of the production valve outlets and seal assemblies 21 and 22 of FIG. 3, for example. The production valve element 21 is arranged in opposed relationship at the opposed ends of the chambers 38 and 39 as illustrated at 21 and 22 in FIGS. 2 and 3.
The chamber 38 of the production end communicates with produced fluid chamber 63 so that a source of production fluid is available at circumferentially spaced apart ports 64 formed within plate member 65. Each of the ports 64 are provided with a valve seat 66 formed in the face of plate member 65 which is opposed to the piston or plunger 37. The seat accommodates each of the ball check valves 67 which are biased against the set by means of the illustrated annular plate 68. Compression spring 69 biases the plate 68 against the balls 67, which is biased against seat 66 of plate 65, thereby maintaining passageways 64 closed to the flow of fluid except in the direction of outlet passageway 70. Outlet passageway 70 communicates with ports 21 which flow into annulus 25 (FIG. 3). This valve can also be used in a number of other double acting pumps.
In operation, the pump of FIGS. 1 and 2 is circulated downhole as a free pump, in a manner known to those skilled in the art, until the seal 16 and nose 12 are seated respective to a seating receptacle, such as seen in FIGS. 2 and 3, for example. In FIGS. 2 and 3, power fluid flows down power oil string 29, into the stinger 14, where power fluid is available at the traveling valve "V" of the engine piston 30, and thereby causes the piston 30 to reciprocate within the engine cylinder, while spent power oil is exhausted to hollow connecting rod 31 and to the sliding guide member 34 and then flows out of the spent power fluid outlets 18.
This action reciprocates pump piston 37 located in the production end 20 of the downhole pump assembly 10. The pump intake 12 provides a source of formation fluid at suction chamber 42 so that the lower rod extension 31" of FIG. 5 receives formation fluid at inlet end 40 (FIG. 3). This provides the traveling valve assembly of the production piston 137 with a source of formation fluid. The formation fluid flows through the valve 52 and to alternate ones of the chambers 38 and 39.
At the same time, produced fluid is forced from the other of the chambers 38 and 39 and through one of the seal and outlet assemblies 21, 22 (FIGS. 2 and 3). The details of one of the valve of the seal and outlet assemblies 21 and 22 are shown in FIG. 7, and it can be seen that fluid flows from production chamber 38, into annular chamber 63, through one of a plurality of circumferentially extending ports 64 which are normally closed by the seated ball check valve 67. The ball check valve 37 is urged into the seated position by the biasing means 68, 69. Pressure differential across the check valve unseats the ball 67 and flow occurs from port 64, across the ball, through passageways 70, and out of the ports 21' where fluid is free to be conducted to the surface of the ground.
An annulus, 73 and 75, is located at opposed end, 77 and 78, of piston 137 and communicates the internal bore, or chamber 55, of the piston 137 with the production chamber 38 and 39. The annulus, 73 and 75, provides a fluid flow passageway through which fluid can be transferred between the opposed variable chambers 55, located at opposed ends of the valve element 52, and the production chambers 38 and 39, each reciprocation of the production piston 137.
The present invention provides a double acting pump which is provided with the maximum size piston in both the engine and the pump end. The guide means 31, 34, 31' interconnectes the engine piston to the pump plunger with a guide device that reduces rod bending and thereby enable a smaller diameter rod to be used. The utilization of the hollow connecting rod together with the traveling valves in both the engine and production piston enables the pistons to be made the very largest possible diameter inasmuch as the necessity of flow ports through the barrel or outer pump housing is obviated by the novel flow system employed by the present invention. | A downhole hydraulically actuated pump assembly has an engine end and a pump end. A traveling valve assembly is included in both the engine end and the pump end. A discharge guide assembly is interposed between the engine and the pump ends, and thereby enables the connecting rod between the engine and pump ends to be greatly increased in length for a specific size. The traveling valve of the pump end includes a lost motion coupling by which the valve is shifted each stroke of the engine. A formation fluid passageway extends from the lower end of the pump, directly through a rod extension, and into the traveling valve. Accordingly, this novel combination and improvements provide a downhole pump assembly having the maximum diameter engine and pump piston. | 5 |
REFERENCE TO CROSS-RELATED APPLICATIONS
[0001] The present application is related and claims priority to U.S. Provisional Patent Application having Ser. No. 60/791,329 having a filing date of Apr. 12, 2006 which is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention generally relates to roof ventilation. More particularly, embodiments of the present invention relate to roof ventilation systems allowing a gas to circulate, between a building attic and ambient.
BACKGROUND OF THE INVENTION
[0003] Ventilating attics helps to prolong shingle life, reduce building cooling costs, and help reduce moisture buildup that can lead to mold, mildew, and rot. Current roof ventilation systems, have shortcomings. For example, they suffer from inadequate compression resistance during installation or subsequent use, have poor resistance to intrusion by precipitation, insects, debris, and lack the capability to be rolled up for storage and transportation. Additionally, current roof ventilation systems often are not universal and cannot be effectively used on a broad range of roofing system, i.e., they cannot be used with differing roofing materials. For example, a shingle roof will require a different roof ventilation system than a slate or standing seam metal roof.
[0004] There exists a need for a roof ventilation system that allows for universal application across a broad range of roofing systems. It is also desired that such a system provide compression resistance without substantially reducing airflow. In addition, there exists a need for a roof ventilation system that allows for substantially net free ventilation area optimization while still resisting wind-driven rain. Furthermore, there exists a need for a ridge vent solution that can be rolled-up to facilitate transportation, storage, and installation on roofs, while still having the ability to lie flat on the roof during installation.
BRIEF DESCRIPTION OF THE INVENTION
[0005] Consistent with embodiments of the present invention a roof ventilation system is disclosed. The preferred systems include a core, a filter, and a spanner. The core preferably conforms to roof surface irregularities. The filter may be configured to hinder rain and debris from entering into an attic while allowing air to flow from, the attic to ambient. The spanner may be configured to allow the roof ventilation system to adjust for varying roof slopes.
[0006] Still consistent with embodiments of the present invention, methods for providing roof ventilation are also contemplated. The methods include providing a core, in which the core provides a space between a ridge cap and a ridge slot, the space allowing air to flow from an attic to ambient. The method may further include providing a barrier allowing air to pass from the attic to ambient yet hindering the passage of rain and debris from passing through the core.
BRIEF DESCRIPTION OF THE FIGURES
[0007] Non-limiting and non-exhaustive embodiments are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
[0008] FIG. 1 shows a perspective of a roof ventilation system consistent with embodiments of the invention;
[0009] FIG. 2 shows a roof ventilation system consistent with embodiments of the invention for installation on a metal roof;
[0010] FIG. 3 shows a roof ventilation system consistent with embodiments of the invention for installation on a shingle roof;
[0011] FIG. 4 shows a cross-sectional view of the roof ventilation system of FIG. 3 taken along line 4 - 4 ;
[0012] FIG. 5 shows an embodiment of the invention having a cast monofilament structure;
[0013] FIG. 6 shows a side cross-sectional view of an embodiment of the invention having, a thermoformed structure;
[0014] FIG. 7 shows several core element shapes consistent with embodiments of the invention; and
[0015] FIG. 8 shows several placements of filter elements consistent with embodiments of the invention.
GENERAL DESCRIPTION
[0016] Ridge venting is a method of forming a vent opening m a roof during construction (or later cut into the roof) that leaves a vent slot along the roof ridge. A core may be placed atop the vent slot to provide a space to allow air to flow from inside the structure by convection, and drawn from the structure by differential pressure. The core may be provided to elevate a ridge shingle or a ridge cap. A filter connected to the core can be used to hinder moisture, debris, and pests from entering the structure through the vent.
DETAILED DESCRIPTION
[0017] Various embodiments are described more My below with reference to the accompanying drawings, which form, a part hereof, and which show specific embodiments of the invention. However, embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art. The following detailed description, accordingly, is not to be taken in a limiting sense.
[0018] Reference may he made throughout this specification to “one embodiment,” “an embodiment,” “embodiments,” “an aspect,” or “aspects” meaning that a particular described feature, structure, or characteristic may be included in at least one embodiment of the present invention. Usage of such phrases may refer to more than, just one embodiment or aspect. In addition, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments or aspects. Moreover, reference to a single item may mean a single item or a plurality of items, just as reference to a plurality of items may mean a single item.
[0019] Referring now to the figures, FIG. 1 shows a perspective of a roof ventilation system 100 consistent with embodiments of the invention. The roof ventilation system 100 has been inverted to show better the underside of a spanning element or spanner 102 , two core elements or cores 104 and 106 and filter elements or filters 108 and 110 . In this perspective view of the roof ventilation system 100 , the spanner 102 may act as a base. The cores 104 and 106 may be attached to the spanner 102 . In addition, the filters 108 and 110 may be attached to either or both the spanner 102 or the cores 104 and 106 . In various aspects of the invention, the spanner 102 , the cores 104 and 106 , and the filters 108 and 110 may have separate materials or design characteristics to best achieve a desired result. The spanner 102 is intended to not only connect the cores 104 and 106 , but also stabilize the roof ventilation system 100 and improve the roof ventilation system's 100 compression resistance.
[0020] The spanner 102 may he formed of a substantially planar, flexible, thermoplastic, non-woven material, such as COLBACK sold by Colbond Incorporated, Enka, N.C., REEMAY sold by Fiberweb, Old Hickory, Tenn. or Spunbond Polyester sold by Johns Manville, Spartanburg, S.C. The non-woven material may be densified by hot calendering. Hot calendering processes may involve passing the material through two rollers wherein at least one roller is heated. The temperature of the rollers may be above the glass transition temperature of the material and below the melting point of the material. Pressure may be applied to the material at a nip point between the rollers. The required pressure may vary with material characteristics, but generally ranges from 100 to 400 pounds per linear inch. The combination of heat and pressure may produce a thinner, denser material. Calendering of the non-woven not only increases the density by reducing the thickness, but may also increase the stiffness and reduce the material bending radius.
[0021] Connecting the spanner 102 to the cores 104 and 106 improves compression resistance and stability yet have a relatively low basis weight. Furthermore, improved compression resistance and stability may be achieved without a loss in air permeability or without losing the ability to roll up the roof ventilations system 100 for transport prior to installation.
[0022] The cores 104 and 106 preferably allow air flow through the roof ventilation system 100 with little or minimized obstruction, provide compression resistance, and enable the roof ventilation system 100 to be applied to a broad range of roofing system, profiles. The cores 104 and 106 are preferably flexible, which allows the roof ventilation system 100 to be rolled and unrolled prior to installation. A combination of stiffness and flexibility of the core material, however, is important to allow utilization across a broad range of roofing systems. The cores 104 and 106 are preferably formed of a thermoplastic material, such as COLBACK, sold by Colbond Incorporated, Enka, N.C. or Spunbond Polyester, sold by Johns Manville, Spartanburg, S.C. In addition, the cores 104 and 106 are formed by hot calendering the thermoplastic material. Hot calendering may improve the thermoplastic material's stiffness, and may also reduce its bending radius. Lowering the material's bending radius allows rolling and unrolling the material without developing cracks or creases to avoid creating permanent deformation. It is desired to avoid permanent deformation is so that the system that will lie substantially flat when unrolled and have improved installation efficiency.
[0023] The cores 104 and 106 may be comprised of a shaped, thermoplastic, and non-woven material. The non-woven may be densified by hot calendering prior to forming cores 104 and 106 into shape. Calendering of the non-woven may increase the stiffness of the non-woven and may enhance the compression resistance. Calendering may also reduce the bending radius of the material allowing the cores 104 and 106 to be rolled and unrolled without permanent deformation. The cores 104 and 106 may be shaped by pleating the calendered or uncalendered material. By way of example and not limitation, the pleating techniques may include score pleating, blade pleating, and gear pleating. The shape of pleated cores 104 and 106 may allow air to escape from inside the building with little or no obstruction, provide enhanced compression resistance, allow the laminate to be tolled and unrolled, and allow the roof ventilation system 100 to be used on a broad range of roofing system profiles (e.g., shingles, metal, slate, etc.).
[0024] The filters 108 and 110 may allow air How from inside the building (e.g., attic) yet hinder intrusion of precipitation, pests, or debris. The filters are preferably formed of Air Lay Nonwoven and sold by Kern-Wove Incorporated, Charlotte, N.C., Spunbond Polyester sold by Johns Manville, Spartanburg, S.C. and Berlin, Germany, REEMAY sold by Fiberweb, Old Hickory, Tenn. and COLBACK sold by Colbond, Incorporated, Enka, N.C. The filters 108 and 110 are preferably conformable to allow the roof ventilation system 100 to adapt to a broad range of roofing system profiles. The filters 108 and 110 may take several, forms, such as a creped pattern. The creping process may compact a substantially planar material and form a plurality of cross-directional folds, or crimps, in the material. The material may be a thermoplastic and may have been, softened by heating. The material may then be allowed to cool under low tension. During the cooling process, the folds may become relatively permanent and may create a stretchable (i.e. elastic) fabric from a formerly planar relatively inelastic fabric. In one aspect of the invention, the filters 108 and 110 may have a 50% to 200% compaction level. In another aspect of the invention, the compaction level may be 75% to 125%.
[0025] The filters 108 and 110 may be formed of a creped or crimped thermoplastic non-woven material. Creping the material may crease an elastic (i.e., stretchable) structure from a formerly planar or inelastic (i.e., non-stretchable structure). The stretchability or extensibility of the creped material may allow it to conform to a broad range of rooting system profiles. Unlike unitary non-woven matting and open-cell foam filters, the filters 108 and 110 may conform to and around roof projections or uneven surfaces. In other words, because the filters 108 and 110 are flexible, they may bend and stretch as needed to conform to roof projections. The creped filters 108 and 110 are less likely to incur a loss of air permeability when installed as compared to other designs. Moreover, by altering the frequency and amplitude of the creped material, it may be possible to increase the net free ventilation area by expanding the materials surface area. For example, by adjusting the frequency of a lightweight thermoplastic non-woven material, to 8-10 crimps per inch and the amplitude to approximately 3 millimeters, the air permeability and net free ventilation area may double. Conversely, increasing the frequency and reducing the amplitude of the creped non-woven material may increase wind-driven rain resistance.
[0026] In connecting the filters 108 and 110 to the cores 104 and 106 , lower levels of compaction may be utilized by attaching the filters 108 and 110 only at selected locations. In other words, the filters 108 and 110 may not be bonded to every core section, that contacts the cores 104 and 106 . By not attaching the filters 108 and 110 to every contact point, additional, material may be available from adjacent sections as needed and the filters 108 and 110 may expand and conform to a roofing system, contour or projection.
[0027] The components (i.e., the spanner 102 , the cores 104 and 106 , and the filters 108 and 110 ) of the roof ventilation system 100 may he bonded to the other components using several different means including, but not limited to, ultrasonic welding, heat bonding, radio frequency welding, mechanical means, and adhesive means. For example, ultrasonic welding, involves converting electrical energy into ultra-high frequency sound waves, creating vibration and frictional beat, within the materials, so that they melt or fuse together. Attachment may also be accomplished by plunge welding or continuous welding the components together.
[0028] Non-woven materials in various aspects of the invention may be broadly classified as bi-component non-woven materials. Bi-component non-woven materials may be formed of two different polymeric materials, in which one component has a substantially lower melting point than the other component. The Bi-component fibers in the non-woven can be formed as core-and-sheath filament, in which the core has the higher melting point component and the sheath has the lower point melting component. In other aspects of the invention, the bi-filament fibers may be made entirely of a higher melting point component and other fibers may be made entirely of a lower melting point component. Other bi-component forms are possible. The lower melting point polymer may serve as an adhesive to bond overlapping or adjacent filaments together while preserving the filament properties of the higher melting point component. The bi-component non-woven material is preferably formed of Spunbond Polyester and sold by Johns Manville, Spartanburg, S.C. and Berlin, Germany, REEMAY sold by Fiberweb, Old Hickory, Tenn. and COLBACK sold by Colbond, Incorporated, Enka, N.C.
[0029] The roof ventilation system 100 cores 104 and 106 and the spanner 102 may have a basis weights between 100 and 550 grams per square meter or, more preferably, between 170 and 250 grams per square meter. The lifters 108 and 110 may have a basis weights between 10 and 150 grams per square meter or, more preferably, between 14 and 100 grams per square meter.
[0030] Turning now to FIG. 2 , the roof ventilation system 100 is shown being installed on a metal roof 204 . The metal roof 204 may include a decking 202 which may be covered by a sheet 206 formed by a plurality of metal panels 208 . The metal roof 204 comes to a ridge 210 at the top of the rafters 212 and forms a slope defined by raters 212 .
[0031] In vented metal roofing systems, the opposed metal sheets do not extend to contact each other at the peak. The gap formed between the metal sheets forms a vent slot, and the vent slot is covered with the roof ventilation system 100 of the present invention. After the roof ventilation system 100 is installed, a ridge cap 214 is placed on top.
[0032] The metal panels 208 typically extend up to within approximately 18 millimeters to 25 millimeters of the ridge 210 . The termination, of the metal panels 208 may define an open vent slot 216 . The juncture of the metal panels 208 at the ridge 210 and the vent slot 216 may be covered with a ridge cap 214 . The ridge cap 214 typically is formed of similar material as the metal panels 208 and may be installed in sections running along the ridge 210 .
[0033] The metal panels 208 may have a plurality of projections 218 that project up from the decking 202 . Adjacent metal panels 208 may be joined together by overlapping lateral edges 220 . The projections 218 are typically comprised of larger stiffening ribs 224 and smaller squared stiffening ribs 218 . The larger stiffening ribs 224 near the lateral edges 220 of the metal panels 208 may be used to overlap the adjacent metal panel 208 .
[0034] Roof ventilation system 100 may have a conformable lower surface comprised of cores 104 and 106 and a filters 108 and 110 that may readily adapt to the metal panels 208 contours, including any projections 218 . The transversely extending peaks and valleys of the cores 104 and 106 may fit over the projections 218 while the filters 108 and 110 may conform to the metal panels' 208 contours. The roof ventilation system 100 may he secured in proximity to an upper edge 228 of the metal panels 208 and may overlay the projections 218 . The spanner 102 may join spaced-apart cores 104 and 106 located on opposite sides of the vent slot 216 . The roof ventilation system 100 may be secured to the metal panels 208 by adhesive or mechanical means as necessary. In addition, the roof ventilation system 100 may he secured to the underside of the ridge cap 214 by adhesive or mechanical means, as necessary.
[0035] It is contemplated, that the ridge cap may act as the spanner 102 . In other words, the cores 104 and 106 may be secured to the ridge cap 214 during, installation. For example, in FIG. 2 , the illustrated spanner 102 may be omitted and the ridge cap 214 may act as the spanner 102 instead. In this configuration, the cores 104 and 106 may he secured to the roof adjacent to the ridge 210 and then the ridge cap 214 may be secured to the roof covering the vent opening yet still allowing air flow from to attic to ambient.
[0036] The ridge cap 214 may overlay the roof ventilation system 100 and may be secured to the metal panels 208 by fasteners 222 . The fasteners 222 may be secured into a plurality of large stiffening ribs. As the ridge cap 214 is secured to the metal panels 208 , the cores 104 and 106 and filters 108 and 110 may be compressed and then may expand to fill an opening between the metal panels 208 and the ridge cap 214 . Ultimately, the filters 108 and 110 may suffer little or no air permeability loss. Air may flow from inside the building through the cores 104 and 106 and through the air filters 108 and 110 or vice versa.
[0037] FIG. 3 shows the roof ventilation system 100 consistent with embodiments of the invention for installation, on a shingle roof 302 . The shingle roof 302 may include a decking 204 which, may be covered by a plurality of asphalt shingles 308 . The shingle roof 312 may comprise a ridge pole 320 placed between the upper ends of the rafters 212 and a collar beam 304 extending between rafters 212 . Roof construction methods may not require the ridge pole 320 (e.g., truss systems).
[0038] The roof decking 204 overlies the roof rafters 212 . Typically, at least one layer of building paper or roofing felt 306 is laid onto the decking to provide at least temporary protection during construction. Since shingle roofs are water shedders and not water-proof, the felt 306 also provides some water resistance protection in later use. A vent slot 216 located at the ridge 210 of the roof may permit the upward and outward air flow, as indicated by arrows 310 , from the building interior by convection and differential pressure. A section of the roof ventilation system 100 is shown covering the vent slot 210 .
[0039] As discussed above, the roof ventilation system 100 may have a conformable lower surface comprised of the cores 104 and 106 and the filters 108 and 110 that may adapt to the shingles 308 contours. The roof ventilation system 100 may be secured in proximity to an upper edge of the decking 204 near the vent slot 216 . The spanner 102 may join the cores 104 and 106 located on opposite sides of the vent slot 216 . The roof ventilation system 100 may be secured to the decking 204 by nails 314 , as necessary. Alternatively, the roof ventilation system 100 may be secured to the shingles 308 by adhesive.
[0040] The cap shingles 312 may overlay the roof ventilation system 100 and may be secured to the decking 204 by nails 314 . Two nails 314 may be placed in each cap shingle 312 and covered by an adjacent cap shingle. As the cap shingles 312 are secured to the decking 204 , the cores 104 and 106 and filters 108 and 110 may expand to till the opening between the decking 204 and the cap shingle 312 thus hindering precipitation, pests, and debris intrusion into the attic. Air may flow flora, inside the building through the cores 104 and 106 and the filters 108 and 110 .
[0041] FIG. 4 shows a cross-sectional view of the roof ventilation system 100 of FIG. 3 taken along line 4 - 4 . The vent slot 216 allows air flow from inside the building space due to convection and differential pressure. The filters 108 and 110 may be bonded to the underside of the spanner 102 and selected valleys of the cores 104 and 106 . The cap shingle 312 may be secured to the roof ventilation system 100 and the decking by a nails 314 .
[0042] FIG. 5 shows an embodiment of the roof ventilation system 100 comprising a cast monofilament structure. Once melted, an extruder develops sufficient pressure to force a molten plastic through a filter and spinnerette or die arrangement. The resulting hot monofilaments are collected, onto a moving die which is shaped in a mirror image of the device. The filaments may be caused to overlap by air currents or by sideways oscillation of the moving die. The shape of the cores 104 and 106 may be spaced apart transversely extending peaks and valleys with overlapping monofilament sidewalls. The spanner 102 may, in an embodiment, be integrated with the cores 104 and 106 and comprised of overlapping monofilaments. The filter 108 may be comprised of a high-loft non-woven. The high loft non-woven material may comprise heavy denier staple fibers such, as 200 to 300 denier per filament staple fiber. The filter 108 may be attached to a planar portion of a cast thermoplastic monofilament structure.
[0043] FIG. 6 shows an embodiment of the roof ventilation system 100 composing a thermoformed structure. The thermoforming may be performed with a pair of matched dies. The thermoplastic material may be preheated before being presented to the dies. The two matched dies may close under pressure to form the spanner 102 and the cores 104 and 106 from a single layer non-woven material.
[0044] The filter 108 may be comprised of open-cell foam. The filter 108 may be attached to a planar portion of the thermoformed structure. The thermoplastic material may be a calendered bi-component non-woven material as described earlier in this specification. The basis weight of the thermoplastic non-woven material may be between 100 grams per square meter and 600 grams per square meter. For example, the basis weight may be between 170 grams per square meter and 350 grams per square meter. The open-cell foam may comprise a polyurethane foam with a porosity of 10 pores per inch to 100 pores per luck. For example, the porosity may be between 20 pores per inch to 50 pores per inch.
[0045] FIG. 7 shows several core shapes that may be used on the roof ventilation system. 100 . All may be shaped to allow the relatively unobstructed airflow from the building inferior, provide structural core compression resistance, allow for universal use on a broad variety of roofing system contours, accept a conformable filter, and allow the roof ventilation system 100 to be rolled and un-rolled, and lie flat prior to installation. The shapes indicated by reference numerals 702 , 714 , and 710 may be formed by pleating or thermoforming a thermoplastic non-woven material or by casting overlapping monofilaments onto a shaped mold. The shapes indicated by reference numerals 706 and 708 may be formed by thermoforming a thermoplastic non-woven material or by casting overlapping monofilaments onto a shaped mold.
[0046] FIG. 8 shows several placements of the filters 108 and 110 consistent with embodiments of the invention. In each case, the filters 108 and 110 may prevent the intrusion of precipitation, pests, and debris into the building interior through the vent slot. The filters 108 and 110 may be attached to the cores 104 and 106 or the spanner 102 by heat bonding, ultrasonic welding, radio frequency welding, or adhesive means. In FIG. 8 a, the filters 108 and 110 may be attached to the underside of the spanner 102 and outboard of the cores 104 and 106 . In FIG. 8 b, the filter 108 may be attached to selected valleys of the cores 104 and 106 and may be intended to cross over the vent slot to permit air flow and prevent intrusion into the building interior. The filler 108 may have relatively high frequency and relatively high amplitude to enhance air flow and wind-driven rain resistance. FIG. 8 c shows the filters 108 and 110 attached to both the valleys of the cores 104 and 106 and the top side of the spanner 102 . In FIG. 8 d, the filters 108 and 110 may be flanked by two core segments 104 a and 104 b, The filters 108 and 110 and core segments 104 a, 104 b, 106 a, and 106 b may be attached to the spanner 102 . The spanner 102 affords installation efficiency as it covers both sides of the vent slot at one instance. Proper selection of the basis weight, crepe characteristics and air permeability of the filters 108 and 110 allow a superior combination of net free ventilation area and resistance to intrusion by precipitation, pests and debris.
[0047] Reference has been made throughout this specification to “one embodiment,” “an embodiment,” or “embodiments” meaning that a particular described feature, structure, or characteristic is included in at least one embodiment of the present invention. Thus, usage of such phrases may refer to more than, just one embodiment. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0048] One skilled in the relevant art may recognize, however, that the invention may be practiced without, one or more of the specific details, or with other methods, resources, materials, etc. In other instances, well known structures, resources, or operations have not been shown or described in detail merely to avoid obscuring aspects of the invention.
[0049] While example embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise configuration and resources described above. Various modifications, changes, and variations apparent to those skilled in the art may be made in the arrangement, operation, and details of the methods and systems of the present invention disclosed herein without departing from the scope of the claimed invention.
[0050] The above specification, examples and data provide a complete description of the manufacture and use of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | System and method for providing a roof ventilation system are disclosed. The roof ventilation system may include a core, a filter, and a spanner. The core may be configured to conform to a roof surface irregularity. The filter may be configured to hinder rain and debris from entering into an attic from ambient yet allow air to flow from the attic to ambient. The spanner may be configured to allow the roof ventilation system of adjust for roof slopes. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to rotary bits for drilling subterranean formations. More specifically, the invention relates to fixed cutter, or so-called "drag" bits, wherein tandem gage pads are employed to provide enhanced stability of the bit while drilling both linear and non-linear borehole segments, and leading surfaces of the trailing or secondary gage pads in the tandem arrangement may be provided with cutters to remove ledging on the borehole sidewall.
2. State of the Art
It has long been known to design the path of a subterranean borehole to be other than linear in one or more segments, and so-called "directional" drilling has been practiced for many decades. Variations of directional drilling include drilling of a horizontal or highly deviated borehole from a primary, substantially vertical borehole, and drilling of a borehole so as to extend along the plane of a hydrocarbon-producing formation for an extended interval, rather than merely transversely penetrating its relatively small width or depth. Directional drilling, that is to say varying the path of a borehole from a first direction to a second, may be carried out along a relatively small radius of curvature as short as five to six meters, or over a radius of curvature of many hundreds of meters.
Perhaps the most sophisticated evolution of directional drilling is the practice of so-called navigational or steerable drilling, wherein a drill bit is literally steered to drill one or more linear and non-linear borehole segments as it progresses using the same bottomhole assembly and without tripping the drill string.
Positive displacement (Moineau) type motors as well as turbines have been employed in combination with deflection devices such as bent housings, bent subs, eccentric stabilizers, and combinations thereof to effect oriented, nonlinear drilling when the bit is rotated only by the motor drive shaft, and linear drilling when the bit is rotated by the superimposed rotation of the motor shaft and the drill string.
Other steerable bottomhole assemblies are known, including those wherein deflection or orientation of the drill string may be altered by selective lateral extension and retraction of one or more contact pads or members against the borehole wall. One such system is the AutoTrak™ system, developed by the INTEQ operating unit of Baker Hughes Incorporated, assignee of the present invention. The bottomhole assembly of the AutoTrak™ system employs a non-rotating sleeve through which a rotating drive shaft extends to drive a rotary bit, the sleeve thus being decoupled from drill string rotation. The sleeve carries individually controllable, expandable, circumferentially spaced steering ribs on its exterior, the lateral forces exerted by the ribs on the sleeve being controlled by pistons operated by hydraulic fluid contained within a reservoir located within the sleeve. Closed loop electronics measure the relative position of the sleeve and substantially continuously adjust the position of each steering rib so as to provide a steady side force at the bit in a desired direction.
In any case, those skilled in the art have designed rotary bits, and specifically rotary drag, or fixed cutter bits, to facilitate and enhance "steerable" characteristics of bits, as opposed to conventional bit designs wherein departure from a straight, intended path, commonly termed "walk", is to be avoided. Examples of steerable bit designs are disclosed and claimed in U.S. Pat. 5,004,057 to Tibbitts, assigned to the assignee of the present invention.
Prevailing opinion for an extended period of time has been that bits employing relatively short gages, in some instances even shorter than gage lengths for conventional bits not intended for steerable applications, facilitate directional drilling. The inventors herein have recently determined that such an approach is erroneous, and that short-gage bits also produce an increased amount of borehole irregularities, such as sidewall ledging, spiraling of the borehole, and rifling of the borehole sidewall. Excessive side cutting tendencies of a bit may lead to ledging of a severity such that downhole tools may actually become stuck when traveling through the borehole.
Elongated gage pads exhibiting little or no side cutting aggressiveness, or the tendency to engage and cut the formation, may be beneficial for directional or steerable bits, since they would tend to prevent sudden, large, lateral displacements of the bit, which displacements may result in the aforementioned so-called "ledging" of the borehole wall. However, a simplistic elongated gage pad design approach exhibits shortcomings, as continuous, elongated gage pads extending down the side of the bit body may result in the trapping of formation cuttings in the elongated junk slots defined at the gage of the bit between adjacent gage pads, particularly if a given junk slot is provided with less than optimum hydraulic flow from its associated fluid passage on the face of the bit. Such clogging of only a single junk slot of a bit has been demonstrated to cause premature bit balling in soft, plastic formations. Moreover, providing lateral stabilization for the bit only at the circumferentially-spaced locations of gage pads comprising extensions of blades on the bit face may not be satisfactory in all circumstances. Finally, enhanced stabilization using elongated gage pads may not necessarily preclude all ledging of the borehole sidewall.
Thus, there is a need for a drill bit which provides good directional stability as well as steerability, precludes lateral bit displacement, enhances formation cuttings removal from the bit, and maintains borehole quality.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a rotary drag bit, preferably equipped with polycrystalline diamond compact (PDC) cutters on blades extending above and radially to the side beyond the bit face, wherein the bit includes tandem, non-aggressive gage pads in the form of primary or longitudinally leading gage pads which may be substantially contiguous with the blades, and secondary or longitudinally trailing gage pads which are at least either longitudinally or rotationally discontinuous with the primary gage pads. Such an arrangement reduces any tendency toward undesirable side cutting by the bit, reducing ledging of the borehole sidewall.
The discontinuous tandem gage pads of the present invention provide the aforementioned benefits associated with conventional elongated gage pads, but provide a gap or aperture between circumferentially adjacent junk slots in the case of longitudinally discontinuous pads so that hydraulic flow may be shared between laterally-adjacent junk slots.
In the case of rotationally-offset secondary gage pads, there is provided a set of rotationally-offset, secondary junk slots above (as the bit is oriented during drilling) the primary junk slots, each of which secondary junk slots communicates with two circumferentially adjacent primary junk slots extending from the bit face, the hydraulic and cuttings flow from each primary junk slot being divided between two secondary junk slots. Thus, a relatively low-flow junk slot is not completely isolated, and excess or greater flows in its two laterally-adjacent junk slots may be contributed in a balancing effect, thus alleviating a tendency toward clogging of any particular junk slot.
In yet another aspect of the invention, the use of circumferentially-spaced, secondary gage pads rotationally offset from the primary gage pads provides superior bit stabilization by providing lateral support for the bit at twice as many circumferential locations as if only elongated primary gage pads or circumferentially-aligned primary and secondary gage pads were employed. Thus, bit stability is enhanced during both linear and non-linear drilling, and any tendency toward undesirable side cutting by the bit is reduced. Moreover, each primary junk slot communicates with two secondary junk slots, promoting fluid flow away from the bit face and reducing any clogging tendency.
In still another aspect of the invention, the secondary gage pads employed in the inventive bit are equipped with cutters on their longitudinally leading edges or surfaces at locations extending radially outwardly only substantially to the radially outer bearing surfaces of the secondary gage pads. Such cutters may also lie longitudinally above the leading edges or surfaces of a pad, but again do not extend beyond the radially outer bearing surface. Such cutters may comprise natural diamonds, thermally stable PDCs, or conventional PDCs comprised of a diamond table supported on a tungsten carbide substrate. The presence of the secondary gage pad cutters provides a reaming capability to the bit so that borehole sidewall irregularities created as the bit drills ahead are smoothed by the passage of the secondary gage pads. Thus, any minor ledging created as a result of bit lateral vibrations or by frequent flexing of the bottomhole assembly driving the bit due to inconsistent application of weight on bit can be removed, improving borehole quality.
Using the tandem gage according to the present invention, a better quality borehole and borehole wall surface in terms of roundness, longitudinal continuity and smoothness is created. Such borehole conditions allow for smoother transfer of weight from the surface of the earth through the drill string to the bit, as well as better tool face control, which is critical for monitoring and following a design borehole path by the actual borehole as drilled.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 comprises a side perspective view of a PDC-equipped rotary drag bit according to the present invention;
FIG. 2 comprises a face view of the bit of FIG. 1;
FIG. 3 comprises an enlarged, oblique face view of a single blade of the bit of FIG. 1;
FIG. 4 is an enlarged perspective view of the side of the bit of FIG. 1, showing the configurations and relative locations and orientations of tandem primary gage pads (blade extensions) and secondary gage pads according to the invention;
FIG. 5 comprises a quarter-sectional side schematic of a bit having a profile such as that of FIG. 1, with the cutter locations rotated to a single radius extending from the bit centerline to the gage to disclose various cutter chamfer sizes and angles, and cutter backrake angles, which may be employed with the inventive bit; and
FIG. 6 is a schematic side view of a longitudinally-discontinuous tandem gage pad arrangement according to the invention, depicting the use of PDC cutters on the secondary gage pad leading edge.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 through 5 depict an exemplary rotary drag bit 200 according to the invention. Bit 200 includes a body 202 having a face 204 and including a plurality (in this instance, six) of generally radially oriented blades 206 extending above the bit face 204 to primary gage pads 207. Primary junk 208 lie between longitudinal extensions of adjacent blades 206, which comprise primary gage pads 207 in the illustrated embodiment. A plurality of nozzles 210 provide drilling fluid from plenum 212 within the bit body 202 and received through passages 214 to the bit face 204. Formation cuttings generated during a drilling operation are transported across bit face 204 through fluid courses 216 communicating with respective primary junk slots 208. Secondary gage pads 240 are rotationally and substantially longitudinally offset from primary gage pads 207, and provide additional stability for bit 200 when drilling both linear and non-linear borehole segments. Shank 220 includes a threaded pin connection 222 as known in the art, although other connection types may be employed.
Primary gage pads 207 define primary junk slots 208 therebetween, while secondary gage pads 240 define secondary junk slots 242 therebetween, each primary junk slot 208 feeding two secondary junk slots 242 with formation cuttings-laden drilling fluid received from fluid courses 216 on the bit face. As shown, the trailing, radially outer surfaces 244 of primary gage pads 207 are scalloped or recessed to some extent, the major, radially outer bearing surfaces 246 of the primary gage pads 207 are devoid of exposed cutters and the rotationally leading edges 248 thereof are rounded or smoothed to substantially eliminate any side cutting tendencies above (in normal drilling orientation) radially outermost cutters 10 on blades 206. Similarly, the radially outer bearing surfaces 250 of secondary gage pads 240 are devoid of exposed cutters for sidecutting, and preferably comprise wear-resistant surfaces such as tungsten carbide, diamond grit-filled tungsten carbide, a ceramic, or other abrasion-resistant material as known in the art. The outer surfaces 250 may also comprise discs, bricks or other inserts of wear-resistant material (see 252 in FIG. 4) bonded to the outer surface of the pads, or bonded into a surrounding powdered WC matrix material with a solidified liquid metal binder, as known in the art. The outer bearing surfaces 246, 250 of respective primary and secondary gage pads 207 and 240 may be rounded at a radius of curvature, taken from the centerline or longitudinal axis of the bit, substantially the same as (slightly smaller than) the gage diameter of the bit, if desired. Further, the secondary gage pads 240 may be sized to define a smaller diameter than the primary gage pads, and measurably smaller than the nominal or gage diameter of the bit 200. As shown in FIGS. 1 and 4, there may be a slight longitudinal overlap between primary gage pads 207 and secondary gage pads 240, although this is not required (see FIG. 6) and the tandem gage pads 207, 240 may be entirely longitudinally discontinuous. It is preferable that the trailing ends 209 of primary gage pads 207 be tapered or streamlined as shown, in order to enhance fluid flow therepast and eliminate areas where hydraulic flow and entrained formation cuttings may stagnate. It is also preferable that secondary gage pads 240 (as shown) be at least somewhat streamlined at both leading edges or surfaces 262 and at their trailing ends 264 for enhancement of fluid flow therepast.
Secondary gage pads 240 carry cutters 260 on their longitudinally leading edges, which in the illustrated embodiment comprise arcuate surfaces 262. As shown, cutters 260 comprise exposed, three-per-carat natural diamonds, although thermally stable PDCs may also be employed in the same manner. The distribution of cutters 260 over arcuate leading surfaces 262 provides both a longitudinal and rotational cutting capability for reaming the sidewall of the borehole after passage of the bit blades 206 and primary gage pads 207 to substantially remove any irregularities in and on the sidewall, such as the aforementioned ledges. Thus, the bottomhole assembly following bit 200 is presented with a smoother, more regular borehole configuration.
As shown in FIG. 6, the bit 200 of the present invention may alternatively comprise circumferentially aligned but longitudinally discontinuous gage pads 207 and 240, with a notch or bottleneck 270 located therebetween. In such a configuration, primary junk slots 208 are rotationally aligned with secondary junk slots 242, and mutual fluid communication between laterally adjacent junk slots (and indeed, about the entire lateral periphery or circumference of bit 200), is through notches or bottlenecks 270. The radial recess depth of notches or bottlenecks 270 may be less than the radial height of the gage pads 207 and 240, or may extend to the bottoms of the junk slots defined between the gage pads, as shown in broken lines. In FIG. 6, the cutters employed on the leading surface 262 of secondary gage pad 240 comprise PDC cutters 272, which may exhibit disc-shaped cutting faces 274, or may be configured with flat or linear cutting edges as shown in broken lines 276. It should also be understood that more than one type of cutter 260 may be employed on a secondary gage pad 240, and that different types of cutters 260 may be employed on different secondary gage pads 240.
To complete the description of the bit of FIGS. 1 through 5, although the specific structure is not required to be employed as part of the invention herein, the profile 224 of the bit face 204 as defined by blades 206 is illustrated in FIG. 5, wherein bit 200 is shown adjacent a subterranean rock formation 40 at the bottom of the well bore. Bit 200 is, as disclosed, believed to be particularly suitable for directional drilling, wherein both linear and non-linear borehole segments are drilled by the same bit. First region 226 and second region 228 on profile 224 face adjacent rock zones 42 and 44 of formation 40 and respectively carry large chamfer cutters 110 and small chamfer cutters 10. First region 226 may be said to comprise the cone 230 of the bit profile 224 as illustrated, whereas second region 228 may be said to comprise the nose 232 and flank 234 and extend to shoulder 236 of profile 224, terminating at primary gage pad 207.
In a currently preferred embodiment of the invention, large chamfer cutters 110 may comprise cutters having PDC tables in excess of 0.070 inch thickness, and preferably about 0.080 to 0.090 inch thickness, with chamfers 124 of about a 0.030 to 0.060 inch width, looking at and perpendicular to the cutting face, and oriented at a 45° angle to the cutter axis. The cutters themselves, as disposed in region 226, are backraked at 20° to the bit profile at each respective cutter location, thus providing chamfers 124 with a 65° backrake. Cutters 10, on the other hand, disposed in region 228, may comprise conventionally-chamfered cutters having about a 0.030 inch PDC table thickness, and a 0.010 inch chamfer width looking at and perpendicular to the cutting face, with chamfers 24 oriented at a 45° angle to the cutter axis. Cutters 10 are themselves backraked at 15° on nose 232 (providing a 60° chamfer backrake), while cutter backrake is further reduced to 10° at the flank 234, shoulder 236 and on the primary gage pads 207 of bit 220 (resulting in a 55° chamfer backrake). The PDC cutters 10 on primary gage pads 207 include preformed flats thereon oriented parallel to the longitudinal axis of the bit 200, as known in the art. In steerable applications requiring greater durability at the shoulder 236, large chamfer cutters 110 may optionally be employed, but oriented at a 10° cutter backrake. Further, the chamfer angle of cutters 110 in each of regions 226 and 236 may be other than 45°. For example, 70° chamfer angles may be employed with chamfer widths (looking vertically at the cutting face of the cutter) in the range of about 0.035 to 0.045 inch, cutters 110 being disposed at appropriate backrakes to achieve the desired chamfer rake angles in the respective regions.
A boundary region, rather than a sharp boundary, may exist between first and second regions 226 and 228. For example, rock zone 46 bridging the adjacent edges of rock zones 42 and 44 of formation 46 may comprise an area wherein demands on cutters and the strength of the formation are always in transition due to bit dynamics. Alternatively, the rock zone 46 may initiate the presence of a third region on the bit profile wherein a third size of cutter chamfer is desirable. In any case, the annular area of profile 224 opposing zone 46 may be populated with cutters of both types (i.e., width and chamfer angle) and employing backrakes respectively employed in region 226 and those of region 228, or cutters with chamfer sizes, angles and cutter backrakes intermediate those of the cutters in regions 226 and 228 may be employed.
Further, it will be understood and appreciated by those of ordinary skill in the art that the tandem gage pad configuration of the invention has utility in conventional bits as well as for bits designed specifically for steerability, and is therefore not so limited.
In the rotationally-offset secondary gage pad variation of the invention, it is further believed that the additional contact points afforded between the bit and the formation may reduce the tendency of a bit to incur damage under "whirl", or backward precession about the borehole, such phenomenon being well known in the art. By providing additional, more closely circumferentially-spaced points of lateral contact between the bit and the borehole sidewall, the distance a bit may travel laterally before making contact with the sidewall is reduced, in turn reducing severity of any impact.
While the present invention has been described in light of the illustrated embodiment, those of ordinary skill in the art will understand and appreciate it is not so limited, and many additions, deletions and modifications may be effected to the invention as illustrated without departing from the scope of the invention as hereinafter claimed. For example, primary and secondary gage pads may be straight or curved, and may be oriented at an angle to the longitudinal axis of the bit, so as to define a series of helical segments about the lateral periphery thereof. | A rotary drag bit being suitable for directional drilling. The bit includes a bit body from which extend radially-oriented blades carrying PDC cutters. The blades extend to primary gage pads, above which secondary gage pads are either longitudinally spaced or rotationally spaced, or both, defining a gap or discontinuity between the primary and secondary gage pads through which drilling fluid from adjacent junk slots may communicate laterally or circumferentially. Longitudinally leading edges of the secondary gage pads may carry cutters for smoothing the sidewall of the borehole. The tandem primary and secondary gage pads provide enhanced bit stability and reduced side cutting tendencies. The discontinuities between the primary and secondary gage pads enhance fluid flow from the bit face to the borehole annulus above the bit, promoting formation cuttings removal. The tandem gage arrangement also has utility in conventional bits not designed specifically for directional drilling. | 4 |
BACKGROUND OF THE INVENTION
[0001] This application is a non-provisional application claiming the benefit of the filing date of Provisional Application Serial No. 60/365,470 filed on Mar. 19, 2002 (now pending). The above application is hereby incorporated by reference for all purposes and made a part of the present disclosure.
[0002] The present invention relates generally to a method and apparatus for harnessing the energy present in an electromagnetic light wave and converting this energy to a form of work, for example, mechanical work.
BRIEF SUMMARY OF THE INVENTION
[0003] In one aspect of the invention, an apparatus is provided for utilizing radiation pressure provided by a light wave to generate mechanical work. The apparatus also includes a containment chamber constructed to contain the propagation of light waves therein along a predetermined reflected light wave path. The apparatus further includes an optic switch selectively operable in an open mode and a closed mode, wherein the open mode allows a light wave to enter the containment chamber and the closed mode prevents escape of the light wave from the containment chamber. Further, the apparatus has a reflective mirror positioned at one end of the containment chamber and second reflective surface positioned at a second end of the containment chamber. The reflective surfaces are positioned so that the predetermined light path extends between the first and second reflective surfaces. The apparatus operates so that repeated contact of the light path against the first reflective surface allows radiation pressure repeatedly acting upon the first reflective surface to cause the movable reflective mirror to travel along a predetermined path. In this way, mechanical work is generated.
[0004] In a preferred embodiment, the inventive apparatus utilizes at least one prism as a light switch and a containment chamber including one or more highly reflective mirrors to reflect propagating light waves in the chamber. In one operative mode, the mirrors absorb radiation pressure and reflect light, thereby converting some of the light energy in the containment chamber into mechanical energy and/or generating work. In one embodiment, the inventive method involves positioning at least two prisms adjacent to one another and by effecting compression between two adjacent faces or walls thereby reduce or eliminate the reflective optical interface between the two, thereby allowing light radiation to pass through as if there were no interface.
[0005] In another aspect of the invention, a method is provided for utilizing radiation pressure provided by a light wave to generate mechanical work. The inventive method includes the initial step of providing a containment chamber for containing propagation of a light wave and positioning, in a first location of the containment chamber, a movable reflective mirror having a first reflective surface. Then, a second reflective surface is positioned in a second location in the containment chamber, whereby the locations and orientations of the first and second reflective surfaces are predetermined to define, at least partially, a predetermined reflective light path. The method then provides for the step of introducing a light wave into the containment chamber. This introducing step includes directing the introduced light wave in the direction of one of the reflective surfaces, thereby causing the light wave to propagate between the first and second reflective surfaces along a predetermined light path for a plurality of cycles. According to the method, the light wave contacts the first reflective surface and causes radiation pressure to act on the first reflective surface, and then reflects against the initial reflective surface at a generally normal angle.
[0006] Preferably, the method further includes repeating the introducing step with respect to another light wave, whereby repeated contact of the first reflective surface with the light wave causes radiation pressure to move the first reflective surface along a predetermined path. More preferably, the positioning step also includes the step of positioning a second movable reflective mirror in the containment chamber, the second reflective mirror having the second reflective surface, and the step of directing the introduced light wave causes the light wave to repeatedly contact the second reflective surface and radiation pressure to repeatedly act upon the second reflective surface, thereby effecting travel of the second reflective surface along a second predetermined path and producing mechanical work.
[0007] Most preferably, the method also includes the step of providing a prism and positioning the prism such that the prism volume forms a portion of the containment chamber and at least one face of the prism forms a boundary of the containment chamber. Thus, the introducing step includes directing the light wave into the prism through said one face.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is simplified schematic of an apparatus, such as a photon engine, for utilizing radiation pressure associated with light waves to generate mechanical work;
[0009] [0009]FIG. 2 is a schematic of one embodiment of a piston assembly for use with the inventive apparatus;
[0010] [0010]FIG. 3 is a schematic of one alternative embodiment of a photon engine according to the present invention;
[0011] [0011]FIGS. 4 a and 4 b are illustrations of prisms that may be used in conjunction with a photon engine according to the present invention;
[0012] [0012]FIG. 5 is a schematic of yet another embodiment of the inventive apparatus; and
[0013] [0013]FIG. 6 is a schematic illustrating one method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIGS. 1 - 6 are provided to illustrate an apparatus and/or method according to the present invention, and embodies various aspects of this invention.
[0015] The present invention relates generally to the utilization of radiation pressure inherent or obtainable from a light wave to produce work, for example, mechanical work. The source of this radiation pressure is provided by a light source, or more specifically, propagating electromagnetic waves directed from a light source into or within the apparatus (i.e. “containment chamber”) of the invention. Generally, the electromagnetic waves are directed into a containment chamber through at least one operable prism that functions in a switching mode. In a preferred embodiment, a primary prism and a secondary prism are used, and are operated together to provide a light switch injection valve, which either reflects light entering the first prism or passes light into the containment chamber.
[0016] Operation of the light switch (shown in FIG. 1) is based on a simple optical phenomenon wherein two individual media( i.e. prisms) may be compressed along an interface so that the media combined act as one. First, light is introduced into the primary prism at a predetermined angle. With the light switch in the closed or non-operative mode, the light reflects off a back face or wall of the primary prism. To open the switch and place it in the operative mode, the primary and secondary prisms, i.e., the first and second individual media, are compressed against each other (or more particularly, the secondary prism compresses against the primary prism) through operation by an external driving device. In doing so, the boundary between the two prisms, i.e., the common face, is removed, and the two media function as one. Light directed into a first prism, therefore, passes through the boundary with the second prism, through the second prism and enters a containment chamber. It is further advantageous to direct light into the primary prism at a predetermined angle so that the light enters and then propagates within the containment chamber at an angle that is normal to a reflective mirror movably mounted within the chamber.
[0017] With light contained in the containment chamber, the light switch is closed. Thus, the light ray or light in the containment chamber maintains columniation and continuously propagates therein. More precisely, the contained light reflects off a first reflective mirror at a normal angle, then against the prism at a nearly 45° angle or other predetermined angle, and then reflects off a second mirror also at a normal angle. These three reflections make up one full cycle which is repeated within a known, predetermined time frame. The time frame also preferably corresponds to the operating frequency of the light switch: between closed and open modes. During each cycle, the light cycles between the three reflective surfaces at high rate so that radiation pressure is transmitted to or through the two mirror surfaces thereby converting or translating the energy of the light wave to mechanical work, i.e., movement of the mirror. In preferred embodiments, the mirror is operatively connected to a piston and contained in a cylinder assembly (the cylinder preferably does not absorb the light) so as to operate as an engine.
[0018] To facilitate description of the invention, a brief explanation of certain concepts is first provided.
[0019] The light wave which is the object of the inventive method is an electromagnetic wave. Electromagnetic waves being an energetic medium transport linear momentum making it possible to exert a mechanical pressure on a surface by shining a light on it the surface. It should be understood that this pressure is small for individual light photons. But given a sufficient number of photons a significant mechanical pressure may be obtained.
[0020] Maxwell (J. C.) showed the resulting momentum p for a parallel beam of light that is totally absorbed is the energy U divided by the speed of light c.
p = U c
[0021] If the light beam is totally reflected the momentum resulting at a normal incidence to the reflection is twice the total absorbed value.
p = 2 U c
[0022] These examples represent the two ends of the spectrum for momentum transfer. The totally absorbed beam at one end that demonstrates the totally inelastic case where the particles stick together and the most kinetic energy is lost, typically, to another form of energy such as thermal energy or deformation. At the other end of the spectrum, a totally reflected beam demonstrates a completely elastic collision where kinetic energy is conserved.
[0023] With reference to FIG. 2, the following sections provide calculations on the power produced by an apparatus and method, i.e. an engine, according to the invention. The calculations can be divided into four sections: Force (F); Time (T); Work (W); and Power (P).
[0024] The following details the force calculation on a single mirror, with surface area, A m , and an initial radiation pressure entering the containment chamber, p 1 , until the radiation pressure is effectively zero after z number of bounces.
F
0-z
=p
1
A
m
+p
2
A
m
+p
3
A
m
+ . . . +p
z
A
m
[0025] The relationship between each radiation pressure bounce can be represented as a function of surface emissivity, ε.
p
2
=εp
1
, p
3
=εp
2
, p
4
=εp
3
, . . . , p
z
=εp
z-1
[0026] Inserting the radiation pressure relationship between bounces off all surfaces results in the following relationship:
F 0 - z , total = p 1 A m + ɛ p 1 A m + ɛ 2 p 1 A m + … + ɛ z p 1 A m or F 0 - z , total = ∑ n = 0 z ɛ n p 1 A m
[0027] For a single mirror every fourth bounce should be added to the force calculation:
F 0 - z , single mirror = p 1 A m + ɛ 4 p 1 A m + ɛ 8 p 1 A m + … + ɛ 4 z / 4 p 1 A m or F 0 - z , single mirror = ∑ n = 0 z / 4 ɛ 4 n p 1 A m
[0028] The time or duration of the force is found by dividing the distance the light travels by the velocity of light.
t=zd/c
[0029] The work of a resultant force on a body equals the change in its kinetic energy. The work calculation for a single piston head is as follows.
W = 1 2 m ( v 2 2 - v 1 2 ) → v 1 = 0 W = 1 2 mv 2 2
[0030] The relationship between velocity, acceleration and force are as follows.
[0031] v=at
F=ma a=F/m
[0032] Therefore,
v=F/m
t
[0033] To obtain the work on a single mirror the force, time and velocity equation are substituted into the work equation.
W single mirror = 1 2 ( ∑ n = 0 z / 4 ɛ 4 n p 1 A m ) 2 ( zd c ) 2 m
[0034] For an emissivity that is nearly equal to one the force exerted on the second mirror is approximately equal to the force on the first mirror. Hence, the sum for work in a single containment chamber is as follows.
W containment chamber ≈ 2 W single mirror = ( ∑ n = 0 z / 4 ɛ 4 n p 1 A m ) 2 ( zd c ) 2 m
[0035] Power is the time rate of doing work. If a single chamber operated continuously, the power would have to account for a full operation or cycle of the cylinder that consists of compression and expansion phases where the force is applied during half the compression phase and removed during the expansion phase.
P containment chamber = 1 4 W containment chamber t or P containment chamber = ( ∑ n = 0 z / 4 ɛ 4 n p 1 A m ) 2 ( zd c ) 4 m
[0036] For a photon engine with 4 containment chambers the power would be as follows.
P photon engine = 4 P containment chamber = ( ∑ n = 0 z / 4 ɛ 4 n p 1 A m ) 2 ( zd c ) m
[0037] Now turning to FIGS. 1 - 6 , these Figures illustrate several embodiments of an apparatus according to the invention. Specifically, each of FIGS. 1, 3, and 5 depict an exemplary photon engine according to the invention.
[0038] [0038]FIG. 1 shows a schematic of a pair of Piston Housings, a Secondary Prism, a Primary Prism (made of a high index of refraction material, >ca. 1.4 such as Crystalline Quartz) a pair of highly reflective mirrors, one disposed in each piston housing, the volume defined by the mirrors and secondary prism further defining a Contaimnent Chamber within a photon engine, a Compression Boundary between the two prisms that can be controlled to form a light switch and a mechanism, for example a piezoelectric mechanism that drives the first Prism and functionally causes the Compression Boundary Light Switch to operate (i.e. allowing light to pass into the containment chamber in a controlled fashion).
[0039] [0039]FIG. 2 is a schematic of one embodiment of a piston assembly of mass m (and a particular area) and emissivity E , being irradiated by a light flux p 1 over a distance d by radiation transmitted through the Compression Boundary Light Switch thereby causing a mechanical force on the piston assembly.
[0040] [0040]FIG. 3 is a schematic of one alternative embodiment of a photon engine showing a pair of prisms, primary and secondary, that when mated along their (“C” in each case) boundary surface form an octagonal cross section switch element that may be further connected with at least a pair of mirror/piston/cylinder assemblies to form a photon engine.
[0041] [0041]FIGS. 4 a and 4 b illustrate prisms in a geometric configuration for a light switch injection valve that may be useful in certain embodiments of a photon engine.
[0042] [0042]FIG. 5 is a schematic of a system to convert radiant energy into a different form of energy or work. The system comprises at least a stand/base member, a pointing controller (for directing the system to a source of radiation) including a motor drive mechanism; a Primary Collector Mirror having an inner parabolic surface covered or coated in a 3M(™) Radiant Light Film, the Mirror mounted on the stand member, the Primary Collector further having at least one parabolic Secondary Collector Mirror mounted thereon, the Secondary Collector also having a 3M Radiant Light File on its outer surface, a light guide for receiving concentrated light from the Secondary Collector Mirror(s) and transmitting the concentrated light to a Photon Engine.
[0043] [0043]FIG. 6 is a schematic illustrating operation of an inventive apparatus, i.e., a a multi-cylinder Photon Engine. The Engine comprises: a plurality of cylinders (e.g. 8 , 9 ); crankshaft and connecting rod assemblies ( 5 , 11 ); pistons/mirror assemblies ( 10 , 12 ); a secondary prism ( 7 ); primary prism ( 6 ); prism piezoelectric drive mechanism ( 14 ); Compression Boundary Light Switch (CBLS), shown as either closed ( 2 ) or open ( 3 ). In practice, light ( 1 ) enters the primary prism ( 6 ) which may be in one of two positions(shown by 2-closed or 3-open), the position effectuated by the CBLS drive mechanism ( 14 ). If the CBLS is closed then incident radiation ( 1 ) will remain in primary prism ( 6 ) as shown by dashed lines) 2 ′). If the piezoelectric drive mechanism ( 14 ) is then engaged, thereby effectively removing the interface as defined by ( 3 ) then light can pass through and generate radiation pressure on mirror/pistons ( 10 and 12 ) thereby displacing them a distance delta x as suggested by ( 13 ) and thereby causing crankshaft 5 to turn thus generating mechanical energy. In another mode the CBLS ( 14 ) may be operated in a frequency modulated mode so that the opening and closing of the light switch allows light to enter the secondary prism ( 7 ) on a time scale related to the frequency of the radiation inside the secondary prism thereby reinforcing the radiation pressure/driving force on the mirrors/piston. and driving crankshaft 15 .
[0044] It should be understood, however, that various arrangements and deployments of the components of inventive apparatus in accordance with the invention may be made and will vary according to the particular environment and applications. However, in any such applications, various aspects of the inventions will be applicable, as described above. For example, various aspects of the photon engine, such as the containment chamber design or the optical switching devices may be incorporated with other engine or mechanical work devices. As a further example, the piston and cylinder assembly may be replaced by another energy system such a energy storage device (e.g., a spring device).
[0045] The foregoing description of the present invention has been presented for purposes of illustration and description. It is to be noted that the description is not intended to limit invention to the apparatus, and method disclosed herein. Various aspects of the invention as described above may be applicable to other types of engines and mechanical work devices and methods for harnessing radiation pressure to generate mechanical work. It is to be noted also that the invention is embodied in the method described, the apparatus utilized in the methods, and in the related components and subsystems. These variations of the invention will become apparent to one skilled in the optics, engine art, or other relevant art, provided with the present disclosure. Consequently, variations and modifications commensurate with the above teachings and the skill and knowledge of the relevant art are within the scope of the present invention. The embodiments described and illustrated herein are further intended to explain the best modes for practicing the invention, and to enable others skilled in the art to utilize the invention and other embodiments and with various modifications required by the particular applications or uses of the present invention. | An apparatus and method provided for utilizing radiation pressure provided by a light wave to generate mechanical work. The apparatus includes a containment chamber constructed to contain the propagation of light waves therein along a predetermined reflected light wave path. The apparatus also an optic switch selectively operable in an open mode and a closed mode, wherein the open mode allows a light wave to enter the containment chamber and the closed mode prevents escape of the light wave from the containment chamber. Further, the apparatus has a reflective mirror positioned at one end of the containment chamber. The reflective mirror has a first reflective surface. The apparatus also includes second reflective surface positioned at a second end of the containment chamber, wherein the predetermined light path extends between the first and second reflective surfaces; and wherein repeated contact of the light path against the first reflective surface allows radiation pressure repeatedly acting upon the first reflective surface to cause the movable reflective mirror to travel along a predetermined path, thereby producing mechanical work. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Pat. App. No. 61/585,038 filed Jan. 10, 2012, the entirety of which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was not federally sponsored.
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] This invention relates to the general field of washing machines, and more specifically toward a cartridge used in a system for dispensing substances into a washing machine utilizing one or more cartridges that contain different substances commonly used in the process of washing clothes. The invention contemplates the use of a plurality of preferably different sized or shaped cartridges that are located within removable drawers. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The washing machine system also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine, hence the cartridge contains a bar code or other readable indicia that communicates with a bar code reader or other reading device located in the washing machine. This bar code or other indicia allows the washing machine to determine whether the cartridge is an original cartridge with contents manufactured, or at least approved, by the company manufacturing the cartridge, or whether it is a re-filled, or even counterfeit cartridge. At the appropriate time, the washing machine dispenses an appropriate amount of substance into the washing machine from the cartridge. This can be accomplished through multiple means. First a pump could pull the substance out of the container and into the washing basin of a washing machine. Alternatively, a valve could be opened and the substance would then pour into the washing basin due to gravitational forces.
[0004] Washing machines enable users to wash their clothes in a shorter period of time and with greater ease than otherwise possible when doing it by hand. Whether it is a top loading or side loading washing machine, the clothes are soaked in water and agitated to get the clothes clean. Often, one or more substances such as laundry detergent, fabric softener, or bleach are added to the water to aid the cleaning process. However, how much of each substance and when it is added depends upon various factors, including the type of substance and the wash cycle set on the washing machine. Many users will place laundry detergent directly into the washing machine as it fills with water, then place fabric softener into a special container that releases the fabric softener at the appropriate time, and may also place bleach into yet another container that releases the bleach at its appropriate time.
[0005] Handling laundry detergent, fabric softener, bleach, or other common substances used to clean clothes can be unpleasant and even harmful. For example, bleach, which may include chlorine, is a respiratory irritant that attacks mucous membranes and can burn the skin. When adding these substances to the washing machine, either into the washing basin or into a separate receptacle, the amount of each substance must be measured. Pouring from a container into a measuring device, and then into the appropriate location in the washing machine often results in inadvertent spills as well as requiring that the measuring device be cleaned.
[0006] Thus there has existed a long-felt need for a system that dispenses an appropriate amount of a particular substance at the appropriate time into a washing machine without requiring a user to potentially come into contact with that substance. Furthermore, there is a need for a system that automatically dispenses a plurality of substances into a washing machine at the appropriate time during a wash cycle.
SUMMARY OF THE INVENTION
[0007] The current invention provides just such a solution by having a system for dispensing substances into a washing machine that relies upon a cartridge that has has been prefilled with a substance useful in the process of washing clothes. A plurality of preferably different sized or shaped cartridges are located within removable drawers in the washing machine. Alternatively, the cartridges can be stored in a stand-alone unit that can be purchased and retrofitted to an existing washing machine. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The washing machine also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine, and the cartridge includes means of allowing the washing machine to identify the substance and the integrity of the cartridge. At the appropriate time, the washing machine dispenses an appropriate amount of substance into the washing machine. A pump pulls the substance out of the cartridge and into the washing basin of a washing machine. Alternatively, a valve is opened and the substance pours into the washing basin due to gravitational forces.
[0008] It is a principal object of the invention to provide a cartridge that enables users to safely, cleanly, and efficiently add substances to a washing machine.
[0009] It is another object of the invention to provide a cartridge that can be used for dispensing of one or more substances into a washing machine at the appropriate time.
[0010] It is a further object of this invention to provide a cartridge which provides a means by which a manufacturer of substances can try to ensure that a cartridge containing this substance cannot be refilled with a competitor's substance and resold.
[0011] It is an additional object of the invention to provide a cartridge where the delivery tube is directed not into the washing machine, but rather to a sprayer, where the sprayer can apply a substance, such as stain remover, to selected parts of selected items of clothing before the actual washing in the washing machine is begun.
[0012] It is yet another object of the invention to provide a dispensing system that is self-contained so as to eliminate pouring a substance form a separate container into a washing machine.
[0013] In a particular embodiment, the current invention is a cartridge that is used in a washing machine system for dispensing a substance into the washing machine comprising a plurality of cartridges, a plurality of level indicators, a plurality of barcode readers, a plurality of dispensing tubes, and a cover, where each cartridge comprises handle, a barcode, a vent, and a delivery tube adapter, where each of the plurality of dispensing tubes mates with a delivery tube of a cartridge, where a substance contained within each cartridge may flow through the delivery tube, where fluid that flows through the delivery tube is inserted into a washing machine, where each level indicator mates with the vent of a cartridge and determines the amount of substance contained within the cartridge, where each barcode reader reads data from a barcode of a cartridge and destroys the barcode of the cartridge, whereby the system for dispensing a substance dispenses a substance from each cartridge at a time and volume determined by the data read from the barcode of each cartridge.
[0014] In another embodiment, the current invention is a method of dispensing a substance into a washing machine comprising the steps of: acquiring a cartridge, having a washing machine accepting a cartridge, where the cartridge comprises a vent and a barcode; scanning the barcode of the cartridge; destroying the barcode of the cartridge such that it cannot be read again; inserting a level indicator through the vent and into the cartridge; and dispensing a substance contained within the cartridge into a washing machine; whereby data collected from scanning the barcode is used to determine the volume and timing of dispensing the substance contained within the cartridge into the washing machine.
[0015] In an additional embodiment, the current invention is a cartridge that can be used in a washing machine system for dispensing a substance comprising: a barcode reader, a level indicator, and a cartridge, where the cartridge comprises a vent and a barcode, where the barcode reader reads the barcode of the cartridge, where the barcode reader destroys the barcode of the cartridge after the barcode reader has read the barcode, where the level indicator is inserted through the vent and determines the level of a substance remaining within the cartridge.
[0016] In a further embodiment, the current invention is a cartridge system for dispensing a substance into a washing machine comprising: at least one cartridge, where the at least one cartridge comprises: six sides that define an inner space, a handle, a barcode, a vent, a delivery tube adapter, and a delivery tube, where the delivery tube adapter mates with the delivery tube, where a substance is contained within the inner space of the cartridge, where the substance may flow through the delivery tube, where the substance that flows through the delivery tube is inserted into a washing machine, where each barcode can contain three or more pieces data, where the three or more pieces of data relate to an identity of the substance, a delivery time which is the time during a washing machine cycle that the substance is to be delivered, and a delivery amount which is the amount of substance to be delivered.
[0017] In yet another embodiment, the current invention is a cartridge system for dispensing a substance into a washing machine comprising: at least one cartridge, where the at least one cartridge comprises: six sides that define an inner space, a handle, a barcode, a vent, a delivery tube adapter, and a delivery tube, where the delivery tube adapter mates with the delivery tube, where a substance is contained within the inner space of the cartridge, where the substance may flow through the delivery tube, where the substance that flows through the delivery tube is inserted into a washing machine, where each barcode can contain three or more pieces data, where the three or more pieces of data relate to an identity of the substance, a delivery time which is the time during a washing machine cycle that the substance is to be delivered, and a delivery amount which is the amount of substance to be delivered, further comprising a level indicator, where the level indicator mates with the vent of a cartridge, where the level indicator measures the amount of substance in the inner space, and displays one or more results from that measurement.
[0018] In an additional embodiment, the current invention is a cartridge system for dispensing a substance into a washing machine comprising: at least one cartridge, where the at least one cartridge comprises: six sides that define an inner space, a handle, a barcode, a vent, a delivery tube adapter, and a delivery tube, where the delivery tube adapter mates with the delivery tube, where a substance is contained within the inner space of the cartridge, where the substance may flow through the delivery tube, where the substance that flows through the delivery tube is inserted into a washing machine, where each barcode can contain three or more pieces data, where the three or more pieces of data relate to an identity of the substance, a delivery time which is the time during a washing machine cycle that the substance is to be delivered, and a delivery amount which is the amount of substance to be delivered, where the number of cartridges is at least two in number, where one of the cartridges comprises a sprayer, where the sprayer comprises a tube that extends from the delivery tube adapter to a spraying device, where the spraying device comprises a trigger that can be pulled to dispense a substance in the cartridge, a handle portion, where the handle portion is shaped like the grip on a handgun, and a dispensing nozzle, where a user can pull the trigger and dispense the substance onto clothes prior to the clothes being inserted into the washing machine.
[0019] In a further embodiment, the current invention is a method of dispensing a substance into a washing machine through a cartridge system, comprising the steps of: accepting a cartridge, where the cartridge comprises: six sides that define an inner space, a handle, a barcode, a vent, a delivery tube adapter, and a delivery tube, where the delivery tube adapter mates with the delivery tube, where a substance is contained within the inner space of the cartridge, where the substance may flow through the delivery tube, where the substance that flows through the delivery tube is inserted into a washing machine, where each barcode can contain three or more pieces data, where the three or more pieces of data relate to an identity of the substance, a delivery time which is the time during a washing machine cycle that the substance is to be delivered, and a delivery amount which is the amount of substance to be delivered; scanning the barcode of the cartridge; destroying the barcode of the cartridge such that it cannot be read again; inserting a level indicator through the vent and into the cartridge; and dispensing a substance contained within the cartridge into a washing machine; whereby data collected from scanning the barcode is used to determine the volume and timing of dispensing the substance contained within the cartridge into the washing machine.
[0020] In another particular embodiment, the current invention is a cartridge system for dispensing a substance comprising: a barcode reader, a level indicator, a cartridge, a second cartridge, a third cartridge, and a dispensing tube, where the cartridge comprises: six sides that define an inner space, a handle, a barcode, a vent, a delivery tube adapter, and a delivery tube, where the delivery tube adapter mates with the delivery tube, where a substance is contained within the inner space of the cartridge, where the substance may flow through the delivery tube, where the substance that flows through the delivery tube is inserted into a washing machine, where each barcode can contain three or more pieces data, where the three or more pieces of data relate to an identity of the substance, a delivery time which is the time during a washing machine cycle that the substance is to be delivered, and a delivery amount which is the amount of substance to be delivered; where the barcode reader reads the barcode of the cartridge, where the barcode reader destroys the barcode of the cartridge after the barcode reader has read the barcode, where the level indicator is inserted through the vent and determines the level of a substance remaining within the cartridge, wherein the cartridge further comprises a dispensing adapter, where the dispensing adapter of the cartridge mates with the dispensing tube, whereby a substance contained within the cartridge may flow through the dispensing adapter and through the dispensing tube, where the second cartridge and the third cartridge each comprise a barcode and a vent, where the second cartridge is smaller than the cartridge, where the third cartridge is smaller than the second cartridge, wherein the cartridge, second cartridge, and third cartridge each contain a substance, where the substance of the cartridge is laundry detergent, where the substance of the second cartridge is fabric softener, and where the substance of the third cartridge is bleach.
[0021] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.
BRIEF DESCRIPTION OF THE FIGURES
[0022] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention.
[0023] FIG. 1 is perspective view of a washing machine with a dispensing system illustrating the location of the cartridges, and some of the accessory parts of a washing machine that utilizes one of more of these cartridges to provide an efficient, clean and safe means by which a person can wash clothes.
[0024] FIG. 2 is a partial view of the dispensing system of the washing machine and the integration of the cartridges into a drawer of a washing machine showing the attachment of the level indicators and delivery tubes in the cartridges.
[0025] FIG. 3 is a perspective view of three cartridges according to selected embodiments of the current disclosure, showing how three cartridges, each of which contain a different substance, would be aligned in the drawers of a washing machine.
[0026] FIG. 4 is a perspective view of a washing machine with a dispensing system and integrated stain remover sprayer according to selected embodiments of the current disclosure.
[0027] FIG. 5 is a perspective view of a cartridge according to selected embodiments of the current disclosure, illustrating its key features.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Many aspects of the invention can be better understood with the references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings.
[0029] FIG. 1 is perspective view of a washing machine with a dispensing system illustrating the location of the cartridges, and some of the accessory parts of a washing machine that utilizes one of more of these cartridges to provide an efficient, clean and safe means by which a person can wash clothes. A cartridge 20 , as described in the claims of this application, is incorporated into a dispensing system 10 which resides on the top of a washing machine 90 . In this particular illustration, cartridge 20 is a cartridge filled with detergent. The dispensing system 10 has a cover 11 that is connected to the back of the dispensing system 10 by a hinge. The dispensing system 10 accepts cartridges, such as a detergent cartridge 20 , fabric softener cartridge 21 , and a bleach cartridge 22 . A level indicator 31 is used to determine the amount of fluid left within each cartridge. Barcode scanners 33 scan the barcode of each cartridge and then puncture (thereby destroying) each barcode after it is scanned. Described in more detail below, the barcode on the cartridge enables the dispensing system to determine what substance is in the cartridge as well as how much of and when to dispense the substance contained therein.
[0030] FIG. 2 is a partial view of the dispensing system and its integration into a drawer of a washing machine according to selected embodiments of the current disclosure, which illustrate the role the cartridge plays in providing the proper amounts of a substance to the washing machine, and how the cartridge interacts with the overall washing machine system. After a cartridge is inserted into the dispensing system, barcode readers 33 scan the barcode ( 25 in FIG. 4 ) of each cartridge. After scanning the barcode, the barcode readers 33 move downward toward the cartridge and pierce each barcode thereby destroying it. By destroying the barcode, the dispensing system prevents repeated use (such as refilling) of the cartridges since the barcode reader 33 will not read a destroyed barcode. The prevention of reuse of the cartridge by a competitor of the manufacturer of the cartridge will optimize profits for the manufacturer by eliminating the opportunity for competitors with lower quality and lower priced substances can refill a cartridge, then resell the cartridge and diminish the reputation of the manufacturer due to having its label on an inferior substance.
[0031] Level indicators 31 are also lowered though a vent in each cartridge. In a particular embodiment, each cartridge has a cap that covers the vent, which is removed before it is inserted into the dispensing system. At the appropriate time, fluid from each cartridge is dispensed through delivery tubes 35 to dispensing tubes 37 , which deposit the fluid in an appropriate area of a cleaning substance drawer 91 of a washing machine. The cleaning substance drawer 91 may include a detergent area 91 , a fabric softener area 93 , and a bleach area 94 . The dispensing tubes 37 deposit the appropriate fluid into the appropriate area.
[0032] FIG. 3 is a perspective view of three cartridges according to selected embodiments of the current disclosure, showing how three cartridges, each of which contain a different substance, would be aligned in the drawers of a washing machine. Three cartridges are shown in this embodiment: a detergent cartridge 20 , fabric softener cartridge 21 , and a bleach cartridge 22 . The detergent cartridge 20 contains laundry detergent and is the largest of the three cartridges shown. The fabric softener cartridge 21 contains fabric softener and is the second largest cartridge shown. The bleach cartridge 22 is the smallest cartridge shown and contains bleach. Each cartridge includes a vent 27 that is covered with a cap (not shown) when stored or otherwise not in use and not inserted within the dispensing system. A barcode 25 is also placed on each cartridge, which is used to identify the particular substance contained within the cartridge and the particular use instructions associated therewith.
[0033] FIG. 4 is a perspective view of a cartridge with an integrated stain remover sprayer according to selected embodiments of the current disclosure. The washing machine dispensing system 10 , in addition to a detergent cartridge, fabric softener cartridge, and bleach cartridge, may include a stain remover cartridge 23 . The stain remover cartridge 23 is designed to allow a user to spray stain remover on particularly dirty portions of clothes. A tube extends therefrom and through an opening in the dispensing system and is connected to a sprayer 39 . The sprayer 39 includes a trigger, which can be pulled to dispense a stain remover substance contained within the stain remover cartridge 23 . Thus, a user may quickly and efficiently treat a stained item of clothing by using the sprayer 39 integrated with the dispensing system 10 .
[0034] FIG. 5 is a perspective view of a cartridge according to selected embodiments of the current disclosure, illustrating its key features. The cartridge 20 , in this case in the shape of a detergent cartridge, includes a handle 26 that is used to grasp the detergent cartridge. A vent 27 is an opening that is used to allow air to enter the detergent cartridge 20 as the substance contained therein is withdrawn. A level indicator (not shown in this figure) may also extend through the vent opening 27 to measure the amount of substance remaining in the detergent cartridge 20 . A barcode 25 identifies that particular substance within the detergent cartridge 20 . The substance within the detergent cartridge 20 is withdrawn through a delivery tube 35 . The delivery tube mates with the detergent cartridge 20 via a dispensing tube adapter 36 . As the detergent cartridge 20 is inserted into the dispensing system, the delivery tube 35 mates the delivery tube adapter 36 , which is integrated into the detergent cartridge.
[0035] The level indicators are inserted through the vent and are used to determine the amount of substance remaining in the particular cartridge. A float moves up and down depending on the level of the substance (fluid) in the cartridge. In other words, as the substance is removed from the cartridge, the float travels downward. Sensors determine the location of the float, and through this the relative amount of substance left in the cartridge.
[0036] In a particular embodiment, the dispensing system includes fluid pumps. The fluid pumps are in fluid connection with the cartridges via delivery tubes. Each fluid pump 50 is in electrical connection to a circuit board, such as a motherboard of the dispensing system or washing machine. Solenoid valves may also be utilized to block and unblock the flow of the fluid from the cartridge and to the washing machine cleaning substance drawer. In this manner, the fluid pump and/or solenoid valves are turned on and off as directed by the internal circuitry of the system and/or washing machine.
[0037] In another embodiment, the dispensing system lacks fluid pumps, and the substance flows from the cartridge through gravity. It is also contemplated that the drawer section of the washing machine could be tilted, or adjustably tilted, such that the gravitational flow is enhanced.
[0038] In another embodiment, the washing machine has drawer capacity to accept four different cartridges, including a stain removing cartridge with an integrated stain remover sprayer. The stain remover cartridge has a sprayer at the end of a tube which is connected to the stain remover cartridge. The sprayer includes a trigger, which can be pulled to dispense a stain remover substance contained within the stain remover cartridge. Thus, a user may quickly and efficiently treat a stained item of clothing by using the sprayer integrated with the dispensing system. It is also contemplated that more than four cartridges could be inserted into one or more drawers in the washing machine.
[0039] In another embodiment, the barcode includes data such as the type of substance within the cartridge, volume of the cartridge, manufacturing date, serial number, or codes or encrypted data that verifies the source and authenticity of the laundry detergent cartridge. By checking the data on the barcode of the cartridge, the system ensures that only compatible cartridges manufactured for the system will dispense the substance contained therein. Furthermore, the appropriate volume and timing of the substance to be dispensed is automatically read in by the system and implemented accordingly, thereby reducing user error.
[0040] In an alternative embodiment, the barcode includes only encrypted identifying data that is used to query a remote network connected server. By way of example, the barcode reader reads in the data from the barcode. It then uses this data to make a request to a remote server over the internet. The request is made as an http request made over a Wi-Fi-network that is connected to the internet. The data from the barcode, either encrypted or decrypted, is transmitted to the remote server, which then responds with various data related to the cartridge. The response data may include confirmation as to whether or not the cartridge is authentic, whether or not the cartridge has been used previously, the substance located within the cartridge, the amount of substance that should be dispensed per load of laundry, at what point in the cycle the substance should be dispensed, and how much substance is located within the cartridge.
[0041] The laundry detergent cartridge includes a vent, handle, and a barcode. The length of the laundry detergent cartridge of a particular embodiment is 14.5 inches, where the handle is 2.5 inches and the remaining portion is 12 inches, and the width of the laundry detergent cartridge is 5.875 inches.
[0042] In an alternative embodiment, the laundry detergent cartridge has a generally trapezoidal shape, where the width of the top part is 5.875 inches and the width of the bottom part is 5.0625 inches. The height of the laundry detergent cartridge is 5.5 inches. The trapezoidal shape helps ensure that the laundry detergent cartridge has the proper orientation when it is placed into the dispensing system. Notches in the laundry detergent cartridge may be used to align the laundry detergent cartridge in the appropriate position and location in the dispensing system.
[0043] A vent cap allows for air to vent into a cartridge as the substance contained within is removed from the cartridge. The vent cap may be a screw-type cap, wherein the vent cap is placed over a vent and screwed into position. When screwed shut, the vent cap closes the vent. When vent cap is unscrewed, the vent is opened and air is allowed to pass therethrough. Without venting the cartridge, fluid would not easily flow out of the cartridge and through the delivery tube.
[0044] The fabric softener cartridge is smaller than the laundry detergent cartridge. Often, more laundry detergent is used than fabric softener per load of laundry. Therefore, the fabric softener cartridge needs to hold less fabric softener than the laundry detergent cartridge needs to hold laundry detergent. In this particular embodiment, the main part of the fabric softener cartridge is 7.125 inches long and 3.5 inches wide. The fabric softener cartridge also includes a handle for grasping and maneuvering the fabric softener cartridge and a vent cap for allowing air to vent into the fabric softener cartridge as fabric softener is removed from the fabric softener cartridge.
[0045] In an alternative embodiment, the fabric softener cartridge has a generally trapezoidal shape, where the width of the top part is 3.5 inches. The height of the fabric softener cartridge is 5.25 inches. The trapezoidal shape helps ensure that the fabric softener cartridge has the proper orientation when it is placed into the dispensing system. Notches in the fabric softener cartridge align the fabric softener cartridge in the appropriate position and location in the dispensing system.
[0046] In a particular embodiment, the laundry detergent cartridge holds 170 oz. of laundry detergent and the bleach cartridge holds 5 oz. of bleach.
[0047] In practice, a user who has purchased one or more cartridges, opens the lid to the dispensing system, removes the vent cap that covers the vent of a cartridge, and then inserts the cartridge into the dispensing system. The user then closes the lid and the dispensing system reads in the barcode located on the cartridge, verifies its authenticity, and then punctures the barcode making it unreadable in the future. If necessary and enabled, the dispensing system queries a remote server for additional information on the cartridge, such as type of substance, size of the container, and dispensing instructions. At the same time or subsequent to reading the barcode, level indicators are inserted through the vent to read in the level of substance remaining within the cartridge.
[0048] Should the user find an unusually large amount of stain on a particular item of clothing, the user can use the sprayer portion of the stain remover cartridge to spray stain remover on the dirty portions prior to starting the normal wash cycle.
[0049] The user will then place dirty laundry into the washing machine, and start a washing cycle. The dispensing system dispenses an appropriate amount of the substance contained within the cartridge into the washing machine at the appropriate time. For example, a first substance may be deposited into the cleaning substance drawer of the washing machine when the cleaning cycle begins, while a second substance is deposited fifteen minutes after the cycle beings, and then a third substance is deposited 5 minutes before the cleaning cycle ends.
[0050] Multiple loads of laundry may be run for each cartridge. When the level indicators determine that there is little substance left within a particular cartridge, such as substance for five or fewer loads, a user is notified. Notifications include without limitation a blinking light, illuminated light, a beep, a buzz, a text message, an email, or red/yellow/green lights and/or bars.
[0051] After a cartridge is empty, the user opens the lid of the dispensing system. As the lid is opened, the level indicators are removed from each cartridge and the user may grasp the handle of the empty cartridge and remove it from the dispensing system. If each cartridge is designed to deliver substance for the same number of loads of laundry, and not necessarily the same amount of substance, then all of the cartridges should need to be replaced at roughly the same time.
[0052] The system described herein has been shown with three different sized cartridges. One skilled in the art will appreciate that fewer or more than three d cartridges of the same or different substances may be implemented. For example, a four-cartridge system may be used where four different substances are desired to automatically dispense into the washing machine. Furthermore, multiple cartridges of the same type and/or size and shape (such as multiple laundry detergent cartridges) may be implemented into the system. Additionally, gravity or pressure pumps may be used to move the fluid substance contained within the cartridge.
[0053] It should be understood that while the preferred embodiments of the invention are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.
[0054] All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved. | A cartridge system for dispensing substances into a washing machine is disclosed. One or more preferably different sized or shaped cartridges are located within removable drawers contained in a washing machine. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The cartridge system also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine. At the appropriate time, the system dispenses an appropriate amount of substance into the washing machine. A pump pulls the substance out of the container and into the washing basin of a washing machine. Alternatively, a valve is opened and the substance pours into the washing basin due to gravitational forces. | 3 |
TECHNICAL FIELD
The present invention relates generally to air-to-air cooling systems, primarily in vehicles with a turbocharging device. More specifically, the present invention relates to air-to-air cooling systems having an aftercooler placed in front of the radiator.
BACKGROUND ART
Referring to FIG. 1, a perspective view of an after cooler-radiator arrangement 30 of the prior art is shown. The physical relationship of an after cooler and a radiator assembly with respect to an engine as a whole is generally described in the detailed description of the preferred embodiment, below. It is important to recognize, with the assembly of FIG. 1, that the aftercooler 31 and radiator assembly 32 are placed one on top of the other such that they receive intake air in parallel. This configuration is to be distinguished from a serial arrangement, in which one unit is placed behind another unit such that air passes through one before the other, i.e., through the after cooler first and then through the radiator assembly or vice versa.
A shortcoming of the arrangement of FIG. 1 is that there is only a finite amount of space available at the front of a car or truck cab for installation of cooling system components. In a parallel configuration the finite amount of space must be split between the radiator assembly 32 and the aftercooler 31. This space limitation may result in cooling system heat exchangers that are of insufficient size to meet heat transfer requirements.
Although the arrangement of FIG. 1 may result in undersized heat transfer components, it is a desired configuration because it allows for easy cleaning. It is quite often the case that the radiator assembly 32 and after cooler 31 become clogged with bugs, plastics, tar, dirt, airborne debris etc, especially on refuse trucks. A parallel arrangement provides easy access to both the aftercooler 31 and the radiator assembly 32 whereby a high pressure water or air hose or similar cleaning device may be used to clear both components.
Referring to FIG. 2, a perspective view of a serial aftercooler/radiator assembly 40 is shown in which the aftercooler 41 and radiator assembly 42 are mounted directly to each other so that no gap is created between the two. This configuration necessitates the disassembly and removal of one, if not both, of the aftercooler 41 and radiator 42 for cleaning and servicing.
SUMMARY OF THE INVENTION
In view of the above shortcomings of the prior art, it is an object of the present invention to provide an after cooler and radiator assembly in a serial arrangement, thereby providing efficient use of space available at the front of a vehicle.
It is yet another object of the present invention to provide an aftercooler and radiator assembly in a serial arrangement to provide larger heat transfer for higher output engines within given vehicle space limitations.
It is another object of the present invention to provide an aftercooler and radiator assembly which is readily cleanable and does not require disassembly or removal of the aftercooler or the radiator from the vehicle for cleaning purposes.
The attainment of these and related objects may be achieved through use of the novel cleanable air to air cooling system herein disclosed. A cleanable air to air cooling system in accordance with this invention has an aftercooler for cooling turbocharged air entering an engine of a motor vehicle. A radiator is provided for cooling fluid circulating in the engine. The radiator is aligned substantially in series with the aftercooler. A spacer is connected between the aftercooler and the radiator. Trap doors are provided in the spacer to permit access to the aftercooler and radiator.
The attainment of the foregoing and related objects, advantages and features of the invention should be more readily apparent to those skilled in the art, after review of the following more detailed description of the invention, taken together with the drawings.
DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a perspective view of the parallel aftercooler and radiator assembly configuration of the prior art.
FIG. 2 is a perspective view of a serial radiator and aftercooler assembly with the after cooler mounted directly to the radiator of the prior art.
FIG. 3 is a diagrammatical plan view of the serial aftercooler and radiator assembly configuration of the preferred embodiment.
FIG. 4 is a perspective view illustrating the cooling system spacer of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 3, a diagrammatical plan view of the aftercooler-radiator assembly 10 of the preferred embodiment is shown. FIG. 3 illustrates a truck engine generally referred to by block 90 indicated by dashed lines. The front tires are also shown by dashed lines. The other components, drawn as solid elements, represent parts of the air and engine cooling system. A basic premise for the preferred embodiment, is to provide an aftercooler 60 and a radiator 65 in such a manner to receive cooling air through the front of a truck in a serial fashion, i.e., air passes through aftercooler 60 and then through radiator assembly 65. The present invention provides a cooling system spacer 63 (hereinafter "spacer 63") which separates the aftercooler 60 from the radiator 65. The spacer 63 permits access to the space between the aftercooler 60 and the radiator 65 for cleaning, inspection and other related activities. This configuration provides sufficient space for air and coolant heat exchangers while at the same time providing easy vehicle cleaning and inspection.
Referring more closely to the arrangement 10 of the preferred embodiment, the engine 90 utilizes a turbo charger 50. The turbo charger 50 is basically an air compressor which compresses air received at intake 54. Turbo chargers are well known in the art and basically work as follows. A power turbine 53 is provided adjacent an exhaust pipe 91. Hot exhaust escaping through the exhaust pipe 91 turns the power turbine 53 which is connected through a common shaft 52 to a second compressor turbine 51 internal to the turbo charger 50. As the power turbine 53 is rotated it in turn rotates the compressor turbine 51, thereby causing the turbocharger 50 to pull in air at intake 54 and compress that air.
The air received at intake 54 is generally at ambient conditions. This air is received through the air cleaner or air filter arrangement of the vehicle. A standard turbo charger 50 increases the pressure and temperature of input air. Although the increased pressure, as will be discussed below, is desirable, the increased temperature is not. Therefore, the pressurized air output from the turbo charger 50 is input to an aftercooler 60 which cools the air via heat exchange to a lower temperature.
Focusing now on the aftercooler 60, the aftercooler 60 is basically an air-to-air heat exchanger. Air is passed from the turbo charger 50 through a transfer tube 57 to input manifold 61. The input manifold basically distributes input air flow for propagation of the hot air into the aftercooler core 60.
The aftercooler 60 is well known in the art and several configurations exist. A common aftercooler 60 configuration is a core matrix wherein tubes carrying air alternate with fins convecting heat away. An outlet manifold 62 is provided for receiving air from the aftercooler core 60. The output manifold 62 receives air from a plurality of tubes in the aftercooler core and converges these tubes into one singular tube for input to the intake manifold 80. Air coming out of the aftercooler 60, travels through transfer tube 81 to the engine intake manifold 80.
Other features of the preferred embodiment include a fan 68 for drawing cooling air through after cooler 60 and radiator 65. The direction of arrows 69 indicates the effect of fan 68 on air intake. Note, however, that the direction of the fan is to some extent arbitrary and it may blow in the other direction. The arrow 70 indicates the direction of air flowing into the front of a vehicle. Air flow (indicated by arrow 70) is also delivered through spacer 63 to the radiator 65 where it provides a similar cooling function for fluids circulating through the engine and passenger compartment. A coolant input 66 and coolant output 67 are indicated to illustrate flow of coolants through the radiator 65. This configuration permits the cooling air flow 70 to provide adequate cooling to turbocharged heated air (at aftercooler 60) and to coolant circulating through the engine 90 and passenger compartment of the vehicle.
Referring to FIG. 4, a perspective expanded view of the after cooler-radiator assembly 10 of the preferred embodiment is shown. The aftercooler 60, as described with respect to FIG. 3, is represented generally by a three-dimensional block. The frame of the radiator assembly 65 is also illustrated. Located between the after cooler 60 and the radiator 65 is a cooling system spacer 63. As discussed with respect to FIG. 3, the spacer 63 permits the aftercooler 60 and radiator 65 to be in a serial arrangement for receiving inflow air, while at the same time providing cleaning, inspection, and easy installation of radiator 65, air aftercooler 60 and related components.
Spacer 63 is dimensionally consistent with the aftercooler 60 and the radiator assembly 65 along its height H and length L. The width, W, of spacer 63 is determined with the following constraints in mind. Trap doors 100-103 are provided for access within the spacer 63. The trap doors 100-103 and spacer 63 configuration are such that it should be relatively easy for a human to reach a hand through the trap doors 100-103 for extending a cleaning implement, e.g., a nozzle of a high pressured air or water hose, for cleaning the radiator 65 without having to remove the aftercooler 60 or radiator 65 from the vehicle. A suggested width of the spacer 63 is three to six inches. The trap doors 100-103 allow for access between components and clean out of any airborne debris that causes plugging and reduced cooling performance. Trap doors also provide for removal of debris and easy access during installation.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents. | An apparatus for a motor vehicle cooling system, comprising an aftercooler for cooling turbocharged air entering an engine of the motor vehicle. A radiator is provided for cooling fluid circulating in the engine. The radiator is aligned substantially in series with the after cooler. A spacer is connected between the after cooler and the radiator. Trap doors are provided in the spacer for accessing the after cooler and radiator. | 5 |
CROSS REFERENCE
This application is a Continuation-in-Part of my prior application Ser. No. 685,251, filed May 11, 1976, and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the shrinkproofing of wool sliver. Disclosed herein is a novel process and an apparatus particularly suitable for carrying out the novel process. Also disclosed herein is a particular solution which is advantageous in the shrinkproofing of wool, not only with the novel apparatus and process disclosed herein but generally in the field of shrinkproofing of wool.
Wool sliver is a commercial product which is produced in a variety of relatively uniform sizes. Sliver is normally described in terms of its quality and in terms of the weight of a 5 yard length of material. Thus, a 21/2 ounce sliver indicates that this particular sliver would weigh 21/2 ounces for a 5 yard length. This sliver would be approximately 1 inch in diameter.
In the normal processing of wool, wool fibers are obtained by clipping from an animal. The clipped fibers are then baled. After collection in bales the raw wool may be scoured and carded. In this state the wool is referred to as card sliver. Card sliver upon combing to remove adventitious materials receives a slight twist and is referred to as top sliver. Top sliver may be drawn such that its diameter is reduced at which time it is then referred to as roving. Roving may be twisted into yarn. Several plies of yarn may be then twisted to form a thread. Generally speaking, wool will be treated while in either the card sliver or top sliver state. However, the invention disclosed hereinafter is useful in any of the stages from card sliver through to thread. Accordingly, the word "sliver" as used hereinafter is intended to be broad enough to encompass card sliver, top sliver, roving, yarn and thread.
It is well known in the prior art that wool sliver may be shrinkproofed by immersing it in an aqueous hypochlorite solution. There has been much technical study and many patents in this field.
It is generally acknowledged that the major reactant involved is hypochlorous acid which is one of the entities in wet chlorine systems, and that the reaction should, as far as possible, be confined only to the surface of the fibers. The reaction between wool and hypochlorous acid tends to be exceedingly rapid and difficult to control so that the major difficulty is one of obtaining "even treatment" of the fibers.
Since the chemical equilibrium involved in HOCl solutions is very pH dependent and since the by-product of the HOCl/wool reaction is the completely dissociated HCl, a self accelerating action is set up at the original reaction site.
Since the rate of the wool/hypochlorous reaction is so fast, it is possible for some of the fibers to be "wetted" by reactant solution which has lost its HOCl content in a first reaction. It is obvious, then, that if the reactant solution is to maintain homogeneity, the rate of its dispersion through the fibers must be faster than the wool/hypochlorous reaction rate if the desired end of even treatment is to be met. To achieve this, several methods have been used to reduce the reaction rate including temperature control; pH modification and addition of sacrificial amino compounds. Any or all of these methods have been coupled with agitation, vibration or wetting agent additions to speed the rate of liquid dispersion. Despite all of this work, the attainment of even treatment is still a major difficulty.
It is in the nature of this invention, that even and homogenous treatment of combed wool sliver can be obtained by use of a mechanical procedure designed to take specific advantage of the geometry of combed wool sliver.
The invention is based in the discovery that the rate of air displacement by the solution for sliver continuously immersed within 10° of the vertical is smooth and even, whereas for sliver immersed horizontally the rate is slow and discontinuous. Because the sliver consists of combed wool fibers, air trapped in the capillaries will be smoothly and uniformly displaced only if the sliver is introduced in the bath in a substantially vertical direction. Immersion of the sliver in the bath in a horizontal direction or nearly horizontal direction will result in entrapment of the air in the capillaries of the sliver and thereby resulting in uneven shrinkproofing of the wool.
Heretofore, wool sliver has been immersed in an appropriate bath at any convenient angle which normally will approach the horizontal. The sliver then travels in a more or less horizontal plane through the bath for an appropriate amount of time to permit treatment by the solution. In order to assist in the treating of the sliver with this type of bath and immersion arrangement the bath is often agitated.
According to this invention the wool sliver is introduced into the bath in a substantially vertical direction and travels downward through the solution in a substantially vertical direction to an appropriate depth. By a suitable choice of the depth to which the sliver is immersed and the rate at which it is carried into the bath, it is possible to obtain even and homogenous filling of the capillary spaces between the combed fibers with reactant liquid in a time less than that required for the wool/hypochlorite reaction. The combed wool sliver (whose capillaries are filled with air) is conveyed substantially vertically into the reactive chlorine solution to a depth of not less than 1 meter at a rate of about 7 centimeters to about 25 centimeters per second. The sliver must be submerged substantially vertically to a depth of at least 1 meter in order that all air may be removed from the capillaries in order that even treatment of the sliver will be achieved. Because the sliver is a relatively delicate product which cannot be subjected to tensile stresses of any significance the sliver may most advantageously be carried into the bath between or on endless screens.
While the sliver is being submerged the air is smoothly displaced from the capillaries by the chlorine liquor. The screens carry the combined wool sliver and capillary liquor around a roll or guide at the bottom of the tank and up through the solution and out of the bath exit.
The sliver now evenly wetted with reactant liquor, is allowed to complete its reaction and is then squeezed, rinsed free from spent liquor and dried.
Sliver so treated is very evenly shrinkproofed and the secondary procedures of attempting to control the rate of reaction by adjustment of pH, of temperature or by adding amino compounds; or of improving the wetting rate by the use of surfactants or agitators or vibrators seem to be unnecessary. The degree of shrinkproofing is easily controlled by adjusting the concentration of hypochlorous acid in the solution.
In essence, an apparatus designed according to this invention consists of a bath of sufficient depth to permit immersion of sliver to a depth of at least 1 meter of fluid. The apparatus will consist of a pulley or guide at the top over which the sliver and its conveying means may be made to pass. A similar pulley or guide will be located at the bottom of the tank. And thirdly, a similar pulley or guide will be located at the exit to withdraw the sliver and conveying means from the tank.
Normally, the final guiding member will be located atop the bath in such a way as to withdraw the wool sliver from the bath as quickly as possible. As the feed rate of sliver is governed by the immersion rate into the bath, obviously withdrawal from the bath in minimum time may only be achieved by removing the sliver according to the shortest path, i.e. vertical. This is desirable although not necessary in order to prevent secondary oxidation by diffusion of more hypochlorous acid. If the sliver is overtreated wool of an unsatisfactory quality and color will result. However, if suitable sealing means could be provided it would be permissible within the terms of this invention to remove the wool sliver from the solution in any particular direction.
Over-treatment of the wool may be easily prevented by use of a U-shaped bath. If a suitable hypochlorous solution is introduced into such a bath at a point relatively near to the point where the wool sliver is introduced, the liquor is fresh. By ensuring a flow of liquor along the U-shaped bath in the same direction of flow as followed by the wool the liquor relatively near the point where the wool is withdrawn from the bath will be weak or spent. Thus, the liquor is caused to flow down one side of the U-shaped bath in which the sliver is traveling downwardly and up in the other leg of the bath. Supply means are incorporated in upper portions of the first mentioned leg of the bath and drain means are provided at the upper end of the second mentioned leg. As the wool sliver is removed from the bath it will of course remove with it some entrapped liquid.
The solution to be used in such a bath is a hypochlorite solution. The best solution known to the inventor is made by passing chlorine gas into water. Such a solution contains less chloride ion than solutions commercially used today, and accordingly has a higher concentration of hypochlorous acid per unit of available chlorine.
Aqueous solutions of hypochlorite are characterized by the uneasy equilibrium between the components. The equilibrium is very pH dependent and can be characterized thus:
OCl+H.sup.+ ⃡HOCl+H.sup.+ +Cl.sup.- ⃡H.sub.2 O+Cl.sub.2 14ΘpH→1
Consequently, the effective concentration of the HOCl entity is dependent on both the total available chlorine of the solution and its pH value.
Shrinkproofing procedures usually operate with solution of about 0.05% hypochlorous acid obtained by different combination of pH and total chlorine (Harris, U.S. Pat. No. 2,466,695; Edwards, British Pat. No. 537,671; Kroy, U.S. Pat. No. 2,671,006). In summary, the overall reaction could be designated as:
Wool+HOCl→oxidized wool+H.sup.+ +Cl.sup.-
The by-product of this reaction (the hydrogen and chloride ions) when released have a very important effect upon the hypochlorite/hypochlorous equilibrium.
In the upper pH conditions (pH 5 to pH 14) the released hydrogen ion converts the unreacted hypochlorite ion to the relatively undissociated hypochlorous acid:
OCl+H.sup.+ →HOCl
This secondary hypochlorous acid can produce localized secondary oxidation which may continue so long as hypochlorite ion is available.
Consequently, alkaline hypochlorination (so-called) tends to produce more secondary oxidation (damage) per degree of primary oxidation (shrinkproofing) and this shows as increased damage to the wool fibers.
To offset this, according to prior art procedures, recourse is had to a very rapid treatment with the hypochlorite solution followed by immersion in a stop bath to destroy the residual hypochlorite. The relatively slow rates of liquid diffusion through wool fibers and the exceedingly fast rate of the wool hypochlorite reactions and hypochlorite/hypochlorous equilibria make the procedure exceedingly difficult.
In acid conditions (pH 5 or less) the release of by-product HCl decreases the HOCl concentration:
HOCl+H.sup.+ +Cl.sup.- ⃡H.sub.2 O+Cl.sub.2
and it is interesting to note that since the by-product releases of H + and Cl - are stoichimetric the rate of the reaction is proportional to the square of the hydrogen ion release concentration. ##EQU1##
Hence release of by-product H + and Cl - from the initial shrinkproofing reaction produces a very dramatic fall in pH equilibrium HOCl content of the shrinkproofing solution.
Consequently, in acid solutions the oxidation by hypochlorous acid is self-limiting at the primary stage and the result is shown in the much lesser degree of damage per effective degree of shrinkproofing.
Commercial hypochlorite solutions have available chlorine values of 1% to 16%. They are invariable alkaline (generally pH 12). They are formed by passing gaseous or liquid chlorine into cooled alkaline solutions. The reaction can be represented thus:
Cl.sub.2 +2NaOH→NaCl=NaOCl+H.sub.2 O+heat
The reaction is generally stopped a little short of the stoichimetric point so as to keep the solution at pH 12.
To make hypochlorous acid solution such commercial hypochlorite solutions are progressively diluted and neutralized with mineral acid, generally muriatic acid.
There are several objections to this procedure:
1. Alkaline hypochlorite solutions undergo steady degradation with time and with temperature thus:
NaClO→Na.sup.+ +Cl.sup.- +(O)↑
Consequently as they age the concentration of chloride ion as a function of available chlorine steadily increases.
2. Acidification means not only the conversion of NaClO to HClO but also the neutralization of the excess alkali in the solution. Consequently this, too, produces an increased concentration of chloride ion as a function of the total available chlorine.
3. The heat of neutralization effectively increases the temperature of the hypochlorous acid solutions and since hypochlorous acid is quite volatile, cooling is required to produce satisfactory shrinkproofing solutions. In such acidified solutions the equilibrium is expressed as: ##EQU2##
It is obvious that increases in the chloride ion concentration of the solution produce a corresponding reduction in the true [HOCl] per unit of total available chlorine.
Contrary to commercial practice today, the pH and available chlorine values are not sufficient to determine the true concentration of HOCl. To determine true [HOCl] consideration must be given to the chloride ion concentration.
Consequently, acidified solutions of commercial alkaline hypochlorite solutions are lower than expected in true concentration of hypochlorous acid.
However, fresh hypochlorous acid solution can be readily obtained by passing chlorine gas into water:
Cl.sub.2 +H.sub.2 O→H.sup.+ +Cl.sup.- +HClO
Such a solution proves to be more advantageous for shrinkproofing because it contains less chloride ion (than the previously described acidified commercial product) and therefore has a higher concentration of hypochlorous acid per unit of available chlorine.
It will be appreciated from the previous description that a solution prepared according to the foregoing method will be essentially self limiting in the wool shrinkproofing reaction. Accordingly, it may be used in any form of bath wherein the solution is evenly distributed throughout the wool sliver. Since the reaction is self limiting, it is not necessary to subject the wool sliver to after bath treatment to stop the chemical reaction in order to obtain acceptable quality shrinkproof wool.
In accordance with this invention, effective shrinkproofing solutions may be obtained by aspirating chlorine into the feed water system of the shrinkproofing process. Solutions of available chlorine (0.05 to 0.25) at pH values at 2.0 to 2.6 and temperatures of 6° C. to 20° C. are easily obtained. As a consequence, neither artificial cooling nor cumbersome neutralization procedures are required according to the invention disclosed herein. It will be particularly obvious that the solution disclosed herein may be used advantageously in conjunction with the method and apparatus disclosed herein to provide a single bath treatment of wool wherein the wool is uniformly treated with little or no danger of secondary treatment and damage to the wool.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE of the drawing is a schematic vertical cross-section taken through an apparatus embodying the invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus designated generally as 1 comprises a container having an outer shell 3 of a hypochloride resistant material, for example polypropylene or polyvinyl chloride, and defines a liquid holding tank. Inserted within the outer shell 2 of the holding tank is a delay tank 5 which acts as a partition to convert the holding tank 2 into a two legged, V-shaped container. Specifically, the delay tank 5 is comprised of a pair of substantially vertical walls 7 and 9 joined by a bottom portion 11. The inside surface of wall 3 and the outside surface of wall 7 are contoured so as to provide a vertical chamber 12 of steadily diminishing cross-section culminating in a non-return valve formed by wipers 13 and 15.
A second chamber 17 formed by walls 3 and 9, going from bottom to top, has a cross-sectional area which steadily increases. As will be seen below, the fluid passing from chamber 12 to 17 has a maximum velocity at the valve formed by wipers 13 and 15, and one formed by a wiper 18, thus obviating the possibility of spent liquor reversing flow as it enters through an inlet 19 in delay tank 5 and flows into chamber 12 through an opening 21.
Positioned under the delay tank 5 is a bottom roller 23 cooperating with the wiper 18 and positioned on an axle 25. An inlet roller 27 is secured to an axle 29, while an outlet roller 31 is secured to an axle 33 such that tangential lines from roller 27 to roller 23 and from roller 23 to roller 31 are substantially vertical. In this manner sliver can be continuously drawn over roller 27, vertically down to roller 23 and then vertically up to roller 31, passing over it and exiting through a pair of gas seal wipers 35 and then between a pair of squeeze rollers 37 and 39 on axles 41 and 43.
While the reaction between the chlorine gas and water is relatively fast, it is not immediate and hence the mixture of chlorine gas and water is injected into delay tank 5 through inlet 19. The reacted mixture then flows up and out of the slot 21 as discussed above. The delay tank 5, having wall 7 slightly angled, provides a delay period of not less than sixty seconds between entry and overflow.
There are two separate endless belts 45 and 47. Belt 45 passes around a roller 49 on an axle 51 through one of a pair of inlet seals 53. The wool sliver enters between belts 45 and 47 over roller 27. As wool sliver is a relatively delicate product which cannot be subjected to tensile stresses, it is conveyed over the roller 27, between belts 47 and 49 down around roller 23 and up over roller 31. Since the belts 45 and 47 which sandwich the wool sliver are of an open mesh type screen, the liquid has easy access to the wool sliver. The screens are composed of material which is resistant to the action of hypochlorous acid solution. As the sliver passes out through seals 35, it passes under a spray rinse nozzle 55 prior to being squeezed between rollers 37 and 39.
Chlorine gas solutions are not only corrosive, but evolve chlorine gas and hypochlorous acid vapors which are highly toxic. All wool and screen inlets to the device are fitted, as discussed above, with inlet and outlet seals 53 and 35, respectively. There is further an exhaust means connected at 57 to ensure that the reaction vessel is kept under negative pressure with a continuous in-flow of air through seals 53 and 35. The spray rinse 55 ensures that all chlorine liquids are removed from the wool and screens prior to exit from the machine.
It would be appreciated from the above discussion that wool is fed into the inlet over roller 27 and down into chamber 12 where it is saturated by the delayed chlorine liquor flowing continuously from outlet 21 in the delay tank 5. The wool and screens pass up through a lower velocity leg in the form of chamber 17 to the roller 31 where the reacted liquor drains from the wool, exiting through a conduit 59, the outlet level of which is below the inlet level seen at 61. Inflow of fresh liquor at 21 is maintained at such a rate as to produce a one way flow throughout.
The length of the bath in the direction perpendicular to the cross-section illustrated in the FIGURE may be any convenient dimension depending on the number of sliver which are intended to be treated at the same time. As stated above, wool sliver may be in the order of 1 to 11/2 inches in diameter. Accordingly, if the bath is required to treat several wool sliver at once in order to match other production, the width of the bath is designed to accommodate the required number of sliver. As most plants will require treatment of more than a single wool sliver at a time, it is suggested that rolls rather than simple pulleys be used to guide the screens. The width of the screens can similarly be chosen to accommodate the number of strands of sliver as desired.
The rate of immersion of the sliver into the bath is controlled by the rate of travel of the screens. An electric motor or other convenient means can be used to drive rolls 27 and 49 or other convenient rolls. It will be appreciated, of course, that in order to prevent damage to the sliver, screens 45 and 47 must travel at the same rate.
As the sliver passes upwardly out of the tank it will pass between the rolls 37 and 39. Rolls 37 and 39 may be conveniently located with their surfaces sufficiently close together to squeeze any excess liquid from the wool sliver. If such a procedure is adopted the excess sliver draining from the capillaries and squeezed from the sliver will together with rinse water from 55 be collected in a trough 63 and exit through an outlet port 65. Thus, the liquid at the exit surface 67 in the upward leg of the bath will be largely spent liquid which is continuously exhausted through outlet 59 to waste. The liquid entering the tank through inlet conduit 19 will be the solution in the desired characteristics of strength, pH and temperature as required.
By use of valves in inlet conduit 19 and outlet conduit 59 the fluid level 61 in the left hand leg 12 is maintained at least 1 meter above the axis of rotation of submerged roll 23. Thus, as the wool sliver travels substantially vertically downward in this leg it will be submerged to a depth of at least 1 meter while traveling in the substantially vertical direction. In this manner, it is ensured that all capillaries of the sliver are completely evacuated of air and filled with reactive liquor.
The apparatus has been illustrated such that each of the conveying screens is guided by a series of six rolls. It will be obvious to those skilled in the art that any number of rolls may be used without departing from the scope of this invention. It will also be obvious that any means of drive could be used to ensure that the two screens travel at the same rate. The only essential is that the lower submerged roll 23 and guide roll 27 must ensure that the sliver enter the bath and travel downwardly therein to a depth of at least 1 meter in a direction which is within 10° or less of the vertical.
While the apparatus disclosed hereinbefore is useful with any of the known shrinkproofing solutions it will be obvious that such apparatus is particularly advantageous when used with the novel solution disclosed herein. As the novel solution disclosed herein is essentially self-limiting in its reaction there will be no need to convey the sliver to a second bath to stop the reaction as the fluid is squeezed from the sliver by roll 37 and roll 39. The sliver may be simply dried and stored for further processing.
Examples illustrating the above-noted invention are set out hereinafter:
EXAMPLE 1
50 Kilograms of a combed wool sliver--64's quality--with a sliver weight of 2 ounces per 5 yards was fed through the machine in the form of 24 parallel slivers at a rate of 18 centimeters per second. The bath contained hypochlorous acid solutions (available chlorine 0.10%) at 8° C. and the tank was kept filled as liquor was continuously removed from it. The exit sliver was squeezed, rinsed and dried. It showed excellent shrinkproofing to standard wash tests and even treatment throughout the sliver in standard dye test.
EXAMPLE 2
50 Kilograms of a combed wool sliver--60's quality, sliver weight--41/2 ounces per 5 yards was fed to the machine as 20 parallel slivers at 18 centimeters per second. The bath contained hypochlorous acid solution (0.12% available chlorine) at 10° C. and was kept filled to offset the liquor continuously removed from it. The final sliver showed excellent and homogenous shrinkproofing throughout.
While the invention has been described, it will be understood that it is capable of further modifications and this application is intended to cover any modifications, uses or adaptations of the invention following in general the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features hereinbefore set forth and as fall within the scope of the invention or limits of the appended claims. | According to the invention disclosed herein wool sliver may be effectively shrinkproofed by immersing the sliver continuously into a bath of shrinkproofing solution to a depth of at least 1 meter if said sliver is carried down into said solution within 10° of vertical. According to the invention the most useful solution is an aqueous solution into which chlorine gas has been aspirated. An apparatus according to the invention comprises a two chambered bath having a delay tank therebetween, having a depth exceeding 1 meter and equipped with means to convey wool sliver into said bath within 10° of vertical. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to knives and, more particularly, to knives having replaceable cutting blades.
2. Brief Description of the Prior Art
Fixed-blade knives are commonly fabricated in the form of a cutting blade that extends from within a fixed handle to a cutting projection wherein the cutting blade has an integral tang that extends into and is secured within the handle. Often, the handle grip is comprised of two side halves that are fastened to either side of the tang so that the handle is a composite of the centrally-disposed tang flanked by the two handle side grip halves. The cutting projection, as an integral projection of the tang, typically comprises an elongated metal member that has a sharpened elongated cutting edge that projects from the handle along one edge of the projection to the tip of the projection. Typical of such knife configurations are hunting knives, kitchen knives and the like. A common characteristic of such knives is that the cutting projection has a substantial thickness so as to impart sufficient stiffness to the sharpened cutting edge. The projecting member is commonly thicker at the handle and progressively thinner toward the tip.
These knives must be periodically resharpened. Under some conditions, such as when out in the field, it is inconvenient or impossible to resharpen the cutting edge at the time most needed. It is often the case, furthermore, that the person using the knife either does not know how to sharpen a knife cutting edge properly or does not have sharpening implements at hand.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a fixed handle knife with a blade projection that incorporates an elongated replaceable cutting element. Another object of the present invention is to provide such a knife where the replaceable cutting element is detachably secured to the elongated side supports that extend alongside and flank the cutting element. A further object of the present invention is to provide such a replaceable cutting element where the element is also detachably secured within the fixed handle. Still another object is to provide such a composite knife blade configuration where the elongated replaceable cutting element is installed and removed by insertion and retraction between the flanking side supports.
These objects and advantages will become apparent from the following description of the invention.
In accordance with these objects and advantages, the invention comprises a knife having a handle section and a blade section, the blade section comprising a pair of opposed flanking side members and a replaceable blade insert confined between the side members and held therebetween. The side members are joined together by a blade insert locator so as to provide a slot for the blade insert. The blade insert is configured to engage with the blade insert locator so as to be held in place in the slot. The blade insert includes a tang configured to extend into the handle section, and the handle section is configured to receive the tang and to confine the tang within the handle section. The handle section includes a tang spacer positioned to separate the side members within the handle section so that the tang fits within the handle section between the side members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the fixed-blade knife of this invention;
FIG. 2 is a perspective view of the elongated replaceable cutting element portion of the FIG. 1 knife;
FIG. 3 is a detail view taken along the line 3--3 in FIG. 1 illustrating the blade projection attachment for the FIG. 2 element;
FIG. 4 is a side elevation view of a handle insert spacer contained within the handle of the FIG. 1 knife;
FIG. 5 is a top view of the FIG. 4 spacer;
FIG. 6 is a top view of the elongated flanking cutting element side support members for the FIG. 1 knife;
FIG. 7 is a side elevation view of one of the flanking side support members that includes a sectional view taken along the line 7--7 in FIG. 6;
FIG. 8 is a bottom view of the FIG. 6 assembly;
FIG. 9 is a rear end elevation view of the FIG. 6 assembly;
FIG. 10 is a top view of one of the handle side halves of the FIG. 1 knife;
FIG. 11 is a top view of the other handle side half of the FIG. 1 knife;
FIG. 12 is a side elevation view of the other flanking side support member;
FIGS. 13-17 are partial side elevation views of the tip portion of the FIG. 1 knife illustrating in sequence the insertion of the replaceable cutting element between the flanking side support members;
FIG. 18 is a partial view in cross section taken along the line 18--in FIG. 10;
FIG. 19 is a partial view in cross section taken along the line 19--in FIG. 11;
FIG. 20 is a top view of the handle end of the FIG. 1 knife with the replaceable cutting element locked into the handle;
FIG. 21 is a partial top view of the handle end of the FIG. 1 knife with the replaceable cutting element unlocked from the handle;
FIG. 22 is a partial side elevation view of a knife handle illustrating an alternative handle lock for locking the replaceable cutting element into the handle;
FIG. 23 is cross section detail view taken along the line 23--23 in FIG. 22;
FIG. 24 is a partial perspective view of the fixed-blade knife of this invention illustrating another alternative handle lock for locking the replaceable cutting element into the handle;
FIG. 25 is a side elevation view of one of the flanking side support members of the FIG. 24 embodiment;
FIG. 26 is a perspective view of the blade insert tang of the FIG. 24 embodiment;
FIG. 27 is a partial side elevation view of a knife handle illustrating provision for the alternative handle lock of the FIG. 24 embodiment;
FIG. 28 is a side elevation view of a handle insert spacer contained with the handle of the FIG. 24 embodiment;
FIG. 29 is a perspective view of the slide of the FIG. 24 embodiment; and
FIG. 30 is a cross-section view taken along the line 30--30 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The fixed-blade knife of this invention comprises a handle section 10 and a blade section 12. The cutting blade section 12 has a first portion that projects from the handle and contains the knife cutting edge, and a second portion that is contained within the handle section. The handle section includes two flanking side grips 14, 16 that confine the tang portion of the blade section 12. Although at a first glance of FIG. 1, the knife might appear as of common construction, the cutting blade section 12 is distinctly different. The cutting blade section is composed of three members, two side support members 18, 20 that flank an intermediate blade insert 22. The blade insert 22 and the flanking side support members are constructed so that the projecting portion of the blade insert is confined and held between the flanking side support members. The blade insert 22, the flanking side support members 18, 20, and the handle grips 14, 16 are constructed so that a rear portion of the blade insert is confined and held within the handle. As a consequence of this construction, the blade insert 22 is supported at two locations: one in the first portion of the blade that projects from the handle; and one in the second portion of the blade that is contained within the handle.
The tang sections of the flanking side support members 18, 20 are confined between the handle grips 14 and 16 and separated by a tang spacer member 24. The tang spacer 24 has a thickness equal to the thickness of the blade insert 22. The flanking side support members 18, 20, the tang spacer 24, and the grips 14, 16 are attached to one another, as by being bonded by an adhesive or cement, or by being mechanically attached by rivets or the like, so as to form in their composite the handle section 10. The tang spacer is also formed at its forward end to provide a seating section 24a for the rear end of the blade insert 22.
The projecting section of the flanking side support members 18, 20 are separated from one another by a blade insert locator member 26. Locator 26 has a thickness equal to the thickness of the blade insert 22. The flanking side support members 18, 20 and the locator 26 are attached to one another as by being mechanically attached by rivets or the like, or welded together. The rear end of the locator 26 is formed to provide a locating and locking edge 26a, and the underside of the locator 26 is formed to provide a blade insert seating edge 26b. The locator 26 may be positioned at a distance about 2/3 of the length of the side support members 18, 20 from the handle section 10. The locator 26 is positioned between the side members 18,20 so that its top edge is flush with the top edges of the side members.
The blade insert 22 is provided with a cutout 30 shaped so that it has a forwardly-pointing rear projection 32a and a bottom edge 32b. Projection 32a is shaped to mate with the locator locking edge 26a, and bottom edge 32b is shaped to mate with the locator blade seating edge 26b, respectively. As a consequence of the matching configurations of projection 32a with locking edge 26a, and of bottom edge 32b with blade seating edge 26b, the blade insert 22 may be placed between the flanking side support members 18, 20, and the cutout 30 engaged with the locator 26 to both locate the blade insert 22 in its proper location as well as lock the blade insert 22 to the projecting portion of the blade 12. FIGS. 13-17 illustrate, in sequence, the placement of the blade insert 22 between the flanking side members 18, 20 and locking the blade insert 22 to the locator 26. As the blade insert 22 is placed between the flanking side members 18, 20, tip first, the cutout projection 32a is engaged with the locking edge 26a so that the blade insert 22 may be pivoted around the locator 26 until the blade insert is fully aligned with the side members. When the blade insert 22 is fully aligned with the flanking side members 18, 20, the top edge of the blade insert will be flush with the top edges of the side members as shown in FIGS. 17 and 1, and the edge of the cutout 30 will completely abut the edge of the locator 26 as shown in FIG. 17. Removing the blade insert 22 can be achieved by reversing the sequence of the procedure shown in FIGS. 13-17.
When the blade insert 22 is fully engaged with the locator 26, as shown in FIG. 17, the blade insert is locked into its relationship with the flanking side support members 18, 20 and the locator 26 against upwardly, downwardly and forwardly directed forces. When fully engaged with the locator 26 as shown in FIG. 17, the blade insert 22 is locked against rearwardly and downwardly directed forces as a result of the mating of the rear end of the blade insert with the seating section 24a of the tang spacer 24. The rear seating section 22a of the blade insert 22 and the upper edge of the seating section 24a are formed so that rear seating section 22a will seat down and against the seating section 24a when the blade insert 22 is placed in its operative position as seen in FIGS. 1 and 17. The rear seating section 22a is formed to provide a substantially vertical back edge 34 that mates with a substantially vertical back edge 36 of seating section 24a, and a forwardly-extending bottom edge 38 that mates with a forwardly-extending top edge 40 of seating section 24a. The abutment of the edges 34 and 36 prevent rearward movement of the blade insert 22. The abutment of edges 38 and 40 prevent downward movement of the rear portion of the blade insert 22.
The flanking side members 18, 20 may be fabricated of a durable, reasonably stiff metal, such as tungsten carbide or stainless steel. Alternately, they may be fabricated from cast steel or bronze, or a suitable engineering plastics material such as fiber glass-filled, or graphite--filled, nylon or polyurethane, and they may be reinforced with graphite fiber laid along the length of the side members. They are shaped in their tang section to conform to the peripheral outline of the handle section 10 as seen in FIGS. 7 and 12. They are shaped in their projecting blade section to have a peripheral outline similar in pattern to the blade insert 22, except that the depth of the side members 18, 20 is sufficiently less than the depth of the blade insert 22 that the blade insert's cutting edge 22b is adequately exposed. The inner surfaces of the side members 18, 20 are parallel and coplaner with the outer surfaces of the blade insert 22 so that the portion of the blade insert that is confined between the side members will abut and be supported by the side member inner surfaces. The outer surface of the projecting portion of each side member, 18, 20, is shaped to taper, as seen at 18a, 20a in FIG. 30, to a very narrow lower edge, as at 42 in FIGS. 1 and 30, so that the transition from the blade insert 22 to the outer surface of each side member is streamlined. To the touch, the lower edges 42 of the side members would feel sharpened and the transition from the blade insert to each side member would be relatively imperceptible. The tips of the side members would likewise be tapered to the fine edge 42 as seen in FIG. 1. The relative thickness of the blade insert 22 and of the tang spacer 24 and blade insert locator 26 are such that the blade insert 22 is confined between the flanking side members 18, 20 in a very close fit. Consequently, the conformation of the outer surface of each side member, leading to the narrow lower edge 42, will provide smooth transitions between the blade insert and the side members so that the composite knife blade of this invention will function as well as a single blade.
The blade insert 22 is preferably fabricated of a metal that retains a sharp edge, such as material from which razor blades are formed. The side surfaces of the blade insert 22 are parallel and coplaner. The blade insert 22 is formed as a thin strip of such material that has a sharpened edge 22b applied after it has been formed. The sharpened edge 22b can be formed in any desired configuration, such as V-shaped, serrated, beveled to provide a single cutting taper, and the like. The sharpened edge may be honed with a sharpening steel without substantially changing the edge bevel. When the blade insert 22 becomes excessively worn, due to resharpening, it may be removed and replaced. Of course, a dull blade insert may be removed and replaced regardless of whether it has ever been resharpened.
The handle section 10 is designed to secure the blade insert 22 in its operative position, the position shown in FIGS. 1 and 17. In general, the handle section 10 may be provided with separate locking means to hold the rear end of the blade insert in the handle section, or the blade insert and the tang sections of the side members 18, 20 may be constructed to provide integral locking means to hold the blade insert into the handle section. To provide separate locking means, an element or elements must be added to the handle section 10 to provide for holding the blade insert in the handle section, such as a side screw, ball detent, clasp, slide or pinned lever designed to engage the rear end of the blade insert. To provide integral locking means, no additional element is required. FIGS. 22-23 illustrate one version of the knife 10 handle section 10 providing separate locking means, FIGS. 24-28 illustrate another version providing separate locking means, and FIGS. 1-2, 10-12 and 18-21 illustrate one version providing integral locking means.
With specific reference to FIGS. 1-2, 10-12 and 18-21, the rear end section of the blade insert 22 may be provided with a locking edge 44 and a disengaging edge 46. One of the side members 18 is notched out at 48 (FIG. 12) to provide a thumb recess and is provided with a tab 50 that is bent into the plane of the blade insert 22. Tab 50 is positioned to overlay the blade insert locking edge 44 when the blade insert is in its operating position as seen in FIG. 1 and 20. The other side member 20 is notched out at 52 (FIG. 7) to provide a gap through which the blade insert edges 44, 46 may be moved to unlock the blade insert from the handle section 10. By pressing laterally against edge 46, edge 44 can be shifted over, from beneath tab 50, so as to free the rear end of the blade insert as seen in FIG. 21. The grip 14, adjacent side member 18, is provided with a thumb recess 54 to expose the blade insert disengaging edge 46. The other grip 16 is provided with a recess 56 to provide a space within which locking edge 44 may be shifted to release it from beneath tab 50. For this feature to be functional, the blade insert 22 must be fabricated from material that is sufficiently flexible that the blade insert edge 44 can be bent as shown in FIG. 21 without exceeding the elastic limit of the material.
When the blade insert 22 has cleared the tab 50, the cutting edge 22b, at a location rearward of locator 26, may be pressed downwardly against an immovable object so as to cause the blade insert's rear end section to pivot upward and out of confinement by the handle section 10. When the rear end section has been pivoted out of the handle section 10, it may be gripped and pulled upward to remove the blade insert 22 from knife.
With specific reference to FIGS. 22 and 23, a set screw 58 may be threaded through one of the grips 16 and through suitable apertures provided in the near side member 20 and the blade insert's rear end section so as to secure the blade insert rear end section within the handle section 10. Alternately, a roll pin or similar shaft element could be extended completely through both grips 14, 16 and both side members 18, 20 to secure the blade insert within the handle section 10. Also, alternately, a sliding plate (not shown) could be mounted into the top of the handle section 10 so as to overlay the blade insert's rear end section so that the plate could be shifted between an overlaying (locking) position and a non-overlayed (unlocked) position. Such a sliding plate could be designed as a flat element to slide laterally forward and rearward. Or the sliding plate could be designed as a slotted sleeve to turn about a longitudinal axis so as to expose the sleeve's slot to the blade insert for disengagement of the blade insert, or to cover the blade insert to lock the blade insert into the handle section.
With specific reference to FIGS. 24-28, the handle 10 may be provided with a slide 60 fitted into appropriately configured notches 62, 64 and 68. The flanking side support members 18, 20 are appropriately notched, as at 62, and the handle flanking grips 14, 16 are appropriately notched at 64. The slide 60 is formed to provide beveled transverse front and rear sides to conform with the similarly configured notches 62, 64. Together, the notches 62, 64 provide a transverse slide slot having the configuration of a trapezoid having parallel top and bottom bases and front and rear non-parallel sides aligned so that the top base is narrower than the bottom base. In the FIG. 24 embodiment, as in the FIG. 1 embodiment, the handle section may also include a tang spacer 24 and, if so, it is provided with an appropriate notch 68 in its top edge 40 to complete the transverse slide slot. The rear edge 44 of the blade insert 22 is likewise preceded by an appropriate notch as seen in FIG. 26. The slide 60 may be shifted to one side or the other so as to expose the blade insert locking edge 44 so that the blade insert 22 may be dislodged and removed from the handle section 10, as heretofore described with reference to the FIG. 1 embodiment. Likewise, the slide 60 may be shifted to one side to expose the slide slot sufficiently that a blade insert may be moved into the handle section 10 and locked therein by shifting the slide 60 back across the transverse slide slot to the closed position shown in FIG. 24.
As seen in FIG. 29, however, it may be preferred to provide slide 60 with a slot 60a through its sloped front edge. Such a slot 60a would be offset from the longitudinal center line of the knife when the slide 60 is positioned in the closed condition shown in FIG. 24. By shifting the slide 60 a small distance, the slot 60a may be aligned with the blade insert locking edge 44 so that the blade insert could be removed from the handle section. Likewise, with the slide 60 shifted to expose the slot 60a to the blade insert recess within the handle section, a blade insert could be positioned within the handle section, and the slide 60 then shifted back to its FIG. 24 position to lock the blade insert within the handle section. With the slot 60a being off center, when the slide 60 is positioned in the closed position shown in FIG. 24, the slot 60a is covered by the handle grip 14 and is, therefore, shielded from becoming plugged with grit or the like from the knife's surroundings.
The structural and functional aspects of the handle section flanking side grips and tang spacer may be combined by being formed, as by plastic or metal molding, into one unitary element having the external and internal configurations illustrated in the drawings. Likewise, the blade section flanking side members may be formed, as by plastic or metal molding, into one unitary element having the external and internal configurations illustrated in the drawings. Moreover, the handle section and the blade section flanking side members may be formed, as by plastic or metal molding, into one unitary element so the only additional elements required for the fixed-blade knife of this invention would be the intermediate blade insert 22 and an appropriate locking means to interact with the handle to hold the blade insert within the handle section.
While the preferred embodiments of the invention has been described herein, variations in the design may be made. For example, whereas certain drawings reflect a design suitable for right-hand use, the same principles could be applied to provide a left-hand version. Various other means locking means are possible to secure the blade insert within the handle, and the three locking means illustrated in the drawings merely serve to show that the locking means may be integrally incorporated into the parts of the knife within its handle section or it may be provided as a separate element or elements mounted within or to the parts within the knife handle section. The scope of the invention, therefore, is only to be limited by the claims appended hereto.
The embodiments of the invention in which an exclusive property is claimed are defined as follows: | A knife having a handle section and a blade section, the blade section comprising a pair of opposed flanking side members and a replaceable blade insert confined between the side members and held therebetween. The side members are joined together by a blade insert locator so as to provide a slot for the blade insert. The blade insert is configured to engage with the blade insert locator so as to be held in place in the slot. The blade insert includes a tang configured to extend into the handle section, and the handle section is configured to receive the tang and to confine the tang within the handle section. The handle section includes a tang spacer positioned to separate the side members within the handle section so that the tang fits within the handle section between the side members. | 1 |
[0001] This application is continuation-in-part of U.S. Patent Application Ser. No. 13/385,847, filed Mar. 9, 2012, which in turn was based on U.S. Provisional Patent Application Ser. No. 61/464,936, filed Mar. 11, 2011, and is also a continuation-in-part of U.S. patent application Ser. No. 09/812,296, filed Mar. 20, 2001, which in turn was based on U.S. Provisional Patent Application Serial No. 60/191,003, filed Mar. 21, 2000, the entire disclosures of each of which are incorporated herein by reference and from each of which priority is claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for displaying live performances on a site on a network, and more particularly, live performances satisfying one or more performance criteria.
BACKGROUND OF THE INVENTION
[0003] Live performances are commonly displayed on sites on networks such as the Internet. In particular, sites which enable selecting and viewing individual performers from a menu featuring a plurality of performers are known. On such sites, for example MyFreeCams.com®, typically a plurality of thumbnails or other displays are offered, each featuring a link to a live performance by an individual performer or group of two or more performers. A viewer of the site typically selects a performer by clicking on or otherwise selecting the performer's image, at which point a window is opened on which the viewer is enabled to view a live display of the selected performer. The selected performer, depending on factors such as viewer requests, viewer payments, individual desire to perform, etc., may engage at a given time in a specific type of performance. For example, in the case of certain live online adult entertainment performances via live videoconferencing, or “live video chat” means, such specific types of performances can be a dance, striptease, nude or semi-nude modeling or video chat. Such a performance can commence subsequent to the viewer's selection of the performer's image or other display, or can be in progress at the time the viewer makes his selection.
[0004] At specific points during the performance, the performer may perform one or more desired acts. Again using adult sexually-oriented live video chat as an example, at a certain time the live video chat performer may remove one or more articles of clothing, such that the performer reveals sufficient portions of her anatomy to be considered topless or nude.
[0005] Particular viewers may desire to view only those performers who presently meet one or more performance criteria, such as performing while topless or nude, available online to teach rock guitar via video conferencing means, available online to provide live video psychological counseling, etc., or available for performances currently or at a specified time in the future.
[0006] A need exists for a method that enables a viewer of a site on a network, such as the Internet, to select and view only performances that meet one or more desired performance criteria, without having to view non-compliant performances.
[0007] A need also exists for a method for marketing a performer whose performance meets one or more performance criteria.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0008] In accordance with one aspect of the present invention, there is provided a method of aggregating access to displays of performances into an aggregate site on a network, the performances originating from at least one performance site on a network. The method includes the steps of: selecting one or more performance criteria; observing at least one performance originating from at least one performance site on a network, the performance being associated with a link; determining when at least one performance meets the performance criterion or criteria; establishing an aggregation link to the link associated with the performance meeting the performance criterion or criteria; and providing the aggregation link to an aggregate site on a network such that the performance is accessible on or via the aggregate site.
[0009] Access to the performance on the aggregate site can, in various particular embodiments, be indirect or direct. Thus, the aggregate site can provide indirect access, via thumbnail photos of the performers, or numbers, symbols, or other abstract indicia of the performers; or direct access, via mini-views of the actual performances in progress. Indirect access can be obtained by activating a thumbnail or other abstract indicium (such as via a mouse- or touchpad-click). In some embodiments, access to the live performance meeting the one or more performance criteria may be effectuated from the aggregate site through a plurality of links which must be sequentially engaged (such as, for example, a link from the aggregate site to a thumbnail link displayed on a website, which when engaged then provides access to a live performance complying with the one or more selected performance criteria). Direct access can be further modified by, e.g., clicking on a “mini-view” thumbnail of live performance in order to access an enlarged or full-screen view of the performance.
[0010] Performances can be aggregated from a variety of performance sites, in various particular embodiments of the inventive method. According to some embodiments, links are established in the aggregate site to specific performances meeting the performance criteria (or display links thereto) displayed on one or more sites that afford access to a plurality of performances, such as MyFreeCams.com® (www.myfreecams.com), Live Jasmine® (www.livejasmine.com), etc. According to other embodiments, links are established to performances displayed on sites maintained, operated or utilized by individual live cam performers which feature a single live cam performer. According to still other embodiments, links to combinations of two or more of the foregoing types of sites are established.
[0011] In some preferred embodiments the aggregated links to performances (e.g., thumbnail links or other indicia links to performances, or “mini views” displaying the live performance in progress) displayed on the aggregation site can be made to appear in a “tube-site” fashion (such as that displayed at www.porntube.com or www.tube8.com) whereby a user is provided with a plurality of selectable mini-view displays of performances in progress or other indicia links to performances of performers who meet the criteria such as being nude or semi-nude at the time of the presentation of the selectable displayed performances or other indicia links to performances. Such dynamic aggregated presentation of accessibility to such performances thereby provides to a user a fast and efficient means of finding and accessing performances that meet a particular criteria or plurality of criteria, such as performers that are performing “nude now” without the need to manually click on a large number of thumbnail links to performances that may or may not meet the performance criterion or criteria (such as is presently the case regarding websites such as MyFreeCams.com®). In some further embodiments, where the dynamic aggregated presentation of accessibility to such performances includes the aggregation of accessibility to performances meeting a criterion or plurality or criteria to or through a plurality of websites that present an aggregation of selectable accessibility to performances (such as a plurality of “live-cam” websites such MyFreeCams.com®, Live Jasmine®, etc.), individual sites (such as individual performer “live-cam” sites), or a combination thereof, which may or may not meet the criteria, the present invention provides the user with a means of more quickly locating and accessing performances that meet the criterion or plurality of criteria.
[0012] In some embodiments, the aggregation of links to performances can be assembled and displayed in response to search queries much the same way as Internet search engines sites assemble search results in response to simple searches, Boolean searches, algorithmic searches or any other desired search methodology. Thus, in response to a search using the search terms of “live”, “nude”, “now”, and “guitar lessons” the live performance aggregation site would generate an aggregation of live performers who are currently nude, live performers currently available to provide guitar lessons and live nude performers currently available to provide guitar lessons.
[0013] In some embodiments, observation or evaluation of the performances to determine if the performances meet the criterion or plurality of criteria according to specific embodiments of the foregoing method are carried out by one or more human observers, who access performance sites via a network, view one or more performances, and determine when selected performance criterion or criteria are met. According to alternative embodiments, some or all of the observation or evaluation functions to determine if the performances meet the performance criterion or plurality of performance criteria are automatically carried out by one or more bots or one or more other automated means. According to alternative embodiments, some or all of the observation functions to determine if the performances meet the criterion or plurality of criteria are carried out in part by one or more humans and in part by one or more bots or one or more other automated means.
[0014] Alternative methods according to the present invention afford direct linkage from a performer's performance site to an aggregate site and/or vice versa. Thus, in accordance with another aspect of the present invention, there is provided a method of aggregating displays of performances into an aggregate site on a network, the performances originating from at least one performance site on a network. The method includes the steps of: selecting a performance criterion; providing at least one performance originating from at least one performance site on a network, the performance being associated with a link; establishing an aggregation link to the link associated with the performance when a performer in the performance determines that the performance meets or will meet the performance criterion; and providing the aggregation link to an aggregate site on a network such that the performance is accessible on the aggregate site. In more specific embodiments, the performer determines that the performance meets, or will at a time in the future meet within a specified time interval, the performance criterion or criteria. It is to be understood that one or more of the steps above may be performed by one or more humans, one or more automated means or a combination thereof.
[0015] Other features and advantages of the present invention will become apparent to those skilled in the art from the preceding and the following detailed description. It is to be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention may be more readily understood by referring to the accompanying drawings in which
[0017] FIGS. 1A-C are illustrations of a monitoring site that monitors one or more live performance sites (as shown, two sites) that feature live performances by human performers, and an aggregate site that displays only such performances as satisfy a performance criterion. FIG. 1A illustrates an initial state of a display at time T 1 in which thumbnails, numbers, symbols or other abstract indicia associated with various performers are presented for determination of compliance with a performance criterion. FIG. 1B illustrates a subsequent state at time T 2 in which compliant performances are identified. FIG. 1C illustrates the aggregation of compliant performances into the aggregate site, where each complaint performance is made available for viewing by a user over a network.
[0018] FIGS. 2A-C are illustrations of a subsequent selection procedure in which one or more performances compliant at time T 2 ( FIG. 2A ) become non-compliant at time T 3 , while other previously non-compliant performances become compliant ( FIG. 2B ). Non-compliant performances are then removed from the aggregate site, while the newly-compliant performances are added to the aggregate site ( FIG. 2C ).
[0019] Like numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] As employed herein, the term “aggregate site” denotes a site on a network at which a plurality of displays are provided, with the displays being directed to the aggregate site from one or more sites on which performances are initially displayed, or are made available by link (e.g., via activation of a thumbnail, number, symbol or other abstract indicium associated with a performer). In some preferred embodiments, such displays are associated with or contain links to the performances that meet the performance criterion or criteria, such that engagement of the link by clicking on the display will cause a user's web browser to connect with the performance that complies with the performance criterion or criteria or a link to the performance that meets the performance criterion or criteria. In some embodiments, the display of thumbnail displays of live performances meeting one or more criteria, or iconic links to such performances, or iconic links to links to such performances can be aggregated to appear a grid-like display similar to “tube sites” that display thumbnail display links to recorded content.
[0021] Referring to FIGS. 1A-C , display 10 provides access to one or more performance sites offering multiple windows 12 each featuring a thumbnail, number, symbol or other abstract indicium associated with a performer. As shown, performance sites 20 A and 20 B offer multiple windows featuring such indicia associated with performers A 1 -A 6 , B 1 -B 6 . At time T 1 , aggregate site 30 initially displays a plurality of blank windows 32 (see FIG. 1A ).
[0022] A human observer of display 10 selects one or more individual performers for viewing, and activates the thumbnail or other indicium associated with the selected performer(s) in order to view their performances. As illustrated, the human observer observes at time T 2 that performers A 1 , A 4 , A 6 , B 1 and B 5 now meet a performance criterion. In particular embodiments, the performers are human females who have removed clothing sufficient to be considered topless, or nude, and thus to comply with the performance criterion of being topless or nude. In FIG. 1B , the human observer selects windows 12 displaying performers A 1 , A 4 , A 6 , B 1 and B 5 engaged in performances compliant with the performance criterion (indicated by dots adjacent each selected window in the exemplary illustration of FIG. 1B , although such displays are optional). The human observer then establishes an aggregation link from the link associated with performances A 1 , A 4 , A 6 , B 1 and B 5 , and provides the aggregation links so established to aggregate site 30 , such that each selected performer is displayed at time T 2 + in an open window 32 of aggregate site 30 ( FIG. 1C ).
[0023] Aggregate site 30 is made available to one or more human viewers over a network, such as the Internet or any other wide-area or local network. Thus, a human viewer of aggregate site 30 is enabled to view only the desired compliant performances, i.e., the performances that meet the performance criterion, without having to search through non-compliant performances before locating a compliant performance. In the foregoing particular embodiments, the human viewer is thus enabled to view only those performers who are presently topless or nude.
[0024] According to particular embodiments, aggregate site 30 is monitored, randomly, periodically or continually, in order to ensure that performance provided on aggregate site 30 meet the site's performance criterion (or criteria). Referring to FIGS. 2A-C , performers A 1 , A 4 , A 6 , B 1 and B 5 from performance sites 20 A, 20 B, respectively, are displayed on aggregate site 30 at time T 2 + ( FIG. 2A ). At time T 3 , a human observer (who can be, in various embodiments, the same observer who initially established aggregation links to the various compliant performances, or a different observer) observes that performer A 1 now does not meet the aforementioned performance criterion, while performers A 2 and A 3 now meet the performance criterion. Thus, performers A 2 , A 3 , A 4 , A 6 , B 1 and B 5 meet the performance criterion at time T 3 . The human observer thus deletes the aggregation link to performer A 1 from the window 32 in aggregate site 30 , and replaces that aggregation link with an aggregation link to performer A 2 . The human observer also establishes an aggregation link to performer A 3 and provides the aggregation link to open window 32 in aggregate site 30 to provide an up-dated display on aggregate site 30 at time T 3 + ( FIG. 2C ). At subsequent times, as performers cease to meet the performance criterion, displays of their performances are removed from aggregate site 30 ; likewise, as new performers meet the performance criterion, displays of their performances are added to aggregate site 30 as window space permits.
[0025] Alternative procedures for ensuring the removal of performances that no longer comply with selected performance criteria are provided in further particular embodiments. According to certain embodiments, aggregation links are periodically or randomly disconnected. For example, in very specific embodiments, some or all aggregation links are subject to “automatic time-out” after a pre-determined time interval, such as 15 or 30 minutes, or alternatively, after a randomly determined time (which may include a minimum time, such as 10 minutes, and a randomly-determined additional time). According to certain other embodiments, disconnection takes place when a previous video display is replaced (e.g., by a performer herself) with a display recognized as no longer meeting the performance criterion. Such displays include, for example, messages indicating that the performance is no longer accessible to viewers generally, such as “I'm in a private show now”. In some further embodiments, the data comprising a display such as one indicating “I'm in a private show now” is recognized by automated means. In still further embodiments the disconnection of the links and/or termination of the display on the aggregation site is effectuated by automated means. According to further embodiments, disconnection takes place when the displayed performance includes insufficient indications of compliance with performance criteria. For example, the displayed performance may no longer exhibit a sufficient display of skin tone to ensure that the performer is topless or nude. Such insufficiency can be recognized, in some specific embodiments, by a human observer as mentioned above, or alternatively, by feature recognition software.
[0026] Certain very specific embodiments of methods according to the invention employ bots to perform some or all of the functions of a human observer or observers, for example by sequentially evaluating performances and applying pattern-recognition software to determine, e.g., the extent of skin exposure, or satisfaction of other performance criteria such as presence of an audio stream, live video transmission, hapitc data stream, etc.
[0027] Many of the foregoing embodiments employ one or more human observers, who are not the performers, or automated means to monitor one or more performance sites featuring a plurality of human performers and add, or delete, links to their performances or links to display links to their performances, to an aggregate site depending upon their compliance or non-compliance with one or more performance criteria. In some alternative embodiments, one or more performers on a performance site or sites may help to increase the viewership potential of their performances by providing notice to the aggregate site of the performer's compliance with the performance criterion or the performers intention or expectation that the performer will do so in the near future. In some particular embodiments, when a performer meets, or anticipates the performer will soon meet, a performance criterion (such as removal of some or all clothing) associated with a particular aggregate site, and desires to have his or her performance added to an aggregate site, the performer himself or herself provides notice to the aggregate site of his or her compliance with the performance criterion. In certain specific embodiments, the performer provides a signal to, or otherwise informs, the aggregate site indicating that compliance with the performance criterion is immediately imminent or currently in progress, and thus that she desires immediate addition of a display link to her performance to the aggregate site. In other specific embodiments, the performer provides notice to the aggregate site that compliance with the performance criterion will occur within a specified time interval or at one or more specified times. For example, the performer might provide notice to the aggregate site that she is one minute away from compliance with the performance criterion, at which point she desires that a display link to her performance be added to the aggregate site.
[0028] The performer can contact the aggregate site by any desired means, e.g., by activating a tab, button or other feature on an appropriate menu or other display provided by the aggregate site (or alternately a third party with which the aggregate site is affiliated) to the performer's computer via the network; .or by alternative means such as personal communication with a human monitor providing aggregation links to the aggregate site as described above. For example, the performer may be provided with functionality on the performer's computer that enables the performer to click on a displayed a button icon (such as one that says “Add to Nude Now Website”, which when clicked by the performer sends a signal to the aggregation site instructing one or more aggregation site computers to establish a link to the performers performance computer and to add a display link to the aggregate site such that a user viewing the aggregate site on his or her computer would be provided with the means to click on the display link to access the performance of the performer. In some preferred embodiments, the signal from the performer to be added to the aggregation site is performed by an assistant or other third-party from the assistant or other third party's computer provided with such signaling functionality or by an automated means as described above where by the meeting of the performance criterion or criteria is detected by automated means. Once the aggregate site is notified of the compliance, the aggregate site (via, e.g., a human monitor, an application maintained by the aggregate site, or other desired means) establishes an aggregation link as described above, and provides the aggregation link to the aggregate site in order to afford access to the performer's performance in an available window or via a displayed link on the aggregate site.
[0029] According to further specific embodiments, a third party, such as a managing studio with which a performer is employed or otherwise affiliated, can contact the aggregate site as described above, i.e., to advise the aggregate site that the performer will comply with the performance criterion immediately or within an indicated time. The third party can thus, in various embodiments, contact the aggregate site as described above, such as by activating an appropriate tab, button or other feature on a display provided to the third party.
[0030] In additional particular embodiments, a performer provides to the aggregate site a premium (e.g., a monetary payment or any other exchange of value) in order to modify the position of the display of his or her performance, or indicia of his or her performance such as a thumbnail, etc., on the aggregate site vis a vis other performances or link to such performances. In very particular embodiments, the greater the value of the premium provided by the performer to the aggregate site, the more favorable the position, size or other beneficial attribute of the display of her performance on the aggregate site. Such favorable positions can include, for example, positions closer to a performance window 32 in an enlarged first position (e.g., upper left) on a display on the aggregate site, or closer to a first page when the aggregate site provides multiple pages each presenting a plurality of performance windows 32 . In some preferred embodiments, the performer provides a premium to the providers of the aggregation website for the purpose of displaying advertising for the performer's upcoming performance(s) that meet the performance criteria or criterion, such as, for example when he or she will next be “nude now”.
[0031] In some embodiments, the operator of aggregate site provides the display of paid advertising in association with the display of live search results resulting from a user search using one or more specified search terms entered by a user of the aggregate site. In some embodiments the amount paid for such advertising by a third party is the highest amount bid for payment to the operator of the aggregate site among other advertisers bidding for the right to display advertising in association with displayed live performance site search results. In some embodiments the operator of the aggregator site can price the cost of publishing the advertising in association with the live site search results displayed based on the locations of the user devices on which such results are displayed. In some preferred embodiments the advertiser can specify the locations of the user computers on which such display advertising is to be displayed. For example, if the aggregate site operator charges more to an advertiser for display of the advertisers advertisement on user devices located throughout the world than on user devices located in the advertiser's home city, the advertiser may wish to have the aggregate site operator limit the publication of the advertisement associated with the search result to devices in the advertiser's home city. Limitation of transmission of such information based on the location of devices can be effectuated by any of the means set forth in U.S. patent application Ser. No. 09/812,296, incorporated herein by reference in its entirety as though set forth in full.
[0032] According to further embodiments of the present invention, a performer provides a premium to the aggregate site in order for her performance to be placed on the aggregate site upon compliance with a performance criterion. In more specific embodiments, the performer's performance is added to a plurality of aggregate sites at which the performer desires to appear upon compliance with appropriate performance criteria associated with such aggregate sites, either upon payment of a single fee or upon payment of a fee for each separate aggregate site.
[0033] Various of the foregoing embodiments aggregate performances obtained from and originally displayed on, or accessible via link from, on one or more sites that afford access to a plurality of performances, such as MyFreeCams.com®; Live Jasmine®, etc. Performances can also be aggregated from sites maintained, operated or utilized by individual performers, such as models, actresses (e.g., “JaneDoe.com”), musicians, singers, etc. Combinations of the foregoing are also within the scope of the present invention. Thus, in some other embodiments of the invention, instead of providing a user with aggregated access to performances of performers that are “nude now” at an one or more aggregation sites, users may be provided with aggregated access to performances meeting one or more other criteria such as persons broadcasting their live travel now from their mobile cams, or persons providing live guitar lessons now, or persons providing live poker play now, etc.
[0034] Some of the foregoing embodiments employ one or more human observers to monitor one or more performance sites featuring a plurality of human performers and add, or delete, links to their performances to an aggregate site depending upon their compliance or non-compliance with one or more performance criteria. In an alternative embodiment, one or more performers on a performance site or sites desire to increase the viewership potential of their performances. In particular embodiments, when a performer meets, or anticipates meeting, a performance criterion (such as removal of some or all clothing) associated with a particular aggregate site, and desires to have her performance added to an aggregate site, the performer herself provides notice to the aggregate site of her compliance with the performance criterion. In certain specific embodiments, the performer provides a signal to, or otherwise informs, the aggregate site indicating that compliance with the performance criterion is immediately imminent or currently in progress, and thus that he or she desires immediate addition of his or her performance to the aggregate site. In other specific embodiments, the performer provides notice to the aggregate site that compliance with the performance criterion will occur within a specified time interval. For example, the performer might provide notice to the aggregate site that he or she is one minute away from compliance with the performance criterion, at which point she desires that her performance be added to the aggregate site.
[0035] The performer can contact the aggregate site to advise the aggregate site of the notice of compliance, or upcoming compliance, with the performance criterion by any desired means, e.g., by activating an application or other functionality via a tab, button or other feature on an appropriate menu or other display provided on the performer's computer or similar device. In some embodiments such functionality is provided to the performer's computer or other device by the aggregate site operator (or alternately a third party with which the aggregate site is affiliated) to the performer's computer or similar device via the network. In some embodiments, the aforesaid notice can be provided by the performer by alternative means such as personal communication with a human monitor providing aggregation links to the aggregate site as described above. Once the aggregate site is notified of the compliance (via, e.g., a human monitor, an application maintained by the aggregate site, or other desired means), the aggregate site establishes an aggregation link as described above, and provides the aggregation link to the aggregate site in order to afford user access to the performer's performance in an available window on the aggregate site.
[0036] According to further specific embodiments, a third party, such as a managing studio with which a performer is employed or otherwise affiliated, can contact the aggregate site as described above, i.e., to advise the aggregate site that the performer will comply with the performance criterion immediately or within an indicated time. The third party can thus, in various embodiments, contact the aggregate site as described above, such as by activating an appropriate tab, button or other feature on a display provided to the third party.
[0037] In additional particular embodiments, a performer provides to the aggregate site a premium (e.g., a monetary payment or any other exchange of value) in order to modify the position of the display of his or her performance, or indicia of his or her performance such as a thumbnail, etc., on the aggregate site vis-a-vis other performances or link to such performances. In some embodiments, the greater the value of the premium provided by the performer to the aggregate site, the more favorable the position, size or other beneficial attribute of the display of his or her performance on the aggregate site. Such favorable positions can include, for example, positions closer to a performance window 32 in an enlarged first position (e.g., upper left) on a display on the aggregate site, or closer to a first page when the aggregate site provides multiple pages each presenting a plurality of performance windows 32 . In some preferred embodiments, the performer provides a premium to the providers of the aggregate website for the purpose of displaying advertising for the performer's upcoming performance(s) that meet the performance criteria or criterion, such as, for example when he or she will next be “nude now”, or when a teacher will next be providing a particular lecture.
[0038] According to further embodiments of the present invention, a performer provides a premium to the aggregate site in order for her performance to be placed on the aggregate site upon compliance with a performance criterion. In more specific embodiments, the performer's performance is added to a plurality of aggregate sites at which the performer desires to appear upon compliance with appropriate performance criteria associated with such aggregate sites, either upon payment of a single fee or upon payment of a fee for each separate aggregate site.
[0039] Various of the foregoing embodiments aggregate performances obtained from and originally displayed on, or accessible via link from, on one or more sites that afford access to a plurality of live performances, such as MyFreeCams.com®, Live Jasmine®, etc. Performances can also be aggregated from sites maintained, operated or utilized by individual performers, such as models, actresses (e.g., “JaneDoe.com”), musicians, singers, teachers, therapists, etc. It is to be understood that combinations of the foregoing are also within the scope of the present invention. Thus, in some other embodiments of the invention, instead of providing a user with aggregated access to performances of performers that are “nude now” at an one or more aggregation sites, users may be provided with aggregated access to performances meeting one or more other criteria such as persons broadcasting their live travel experiences now from their mobile cams, or persons providing live guitar lessons now, persons providing live life coaching or live therapy now, or persons providing live poker play now, etc.
[0040] The foregoing embodiments of methods according to the invention make use of observers (e.g., humans or bots or other automated means) to determine compliance with performance criteria. Alternative methods according to the present invention afford direct linkage from a performer's performance site to an aggregate site. In such embodiments, the performer himself or herself establishes an aggregation link to the link associated with her performance when she determines that the performance meets or will meet the performance criterion, and then provides the aggregation link to an aggregate site. In more specific embodiments, the performer determines that the performance meets the performance criterion or will meet the performance criterion within a specified time interval, and then establishes the aggregation link as described.
[0041] Methods according to the invention can be used to aggregate and searchably display any type of live performance for which aggregation at an aggregate site is desired, and methods according to the invention may also be used employ any desired performance criterion or criteria for displayed aggregation. Non-limiting exemplary types of performances include dances; dramatic performances (e.g., plays, readings of prose or poetical works.); musical performances (e.g., singing, playing musical instruments); consultations and other live services by professionals, such as legal professionals (e.g., attorneys, paralegals), financial professionals (e.g., accountants, tax preparers), medical professionals (e.g., doctors, nurses), therapists, life coaches, teachers, and lecturers, and gaming performances, such as live video gaming, gambling performances, such as poker play; and the like, such performances being made by single performers or groups of two or more performers. Non-limiting exemplary performance criteria include physical characteristics (e.g., eye color, hair color, hair length, race, ethnicity, age, sex, physical measurements such as height, weight and bust size, alone or in combination); performance type (e.g., playing guitar); professional specialization (e.g., corporate law, patent law, bankruptcy law, internal medicine, pediatrics); and performance activity, such as broadcasting travel via mobile phone cam, or remote shopping or travel assistance as described, for example, in U.S. Provisional Patent Application Ser. No. 61/626,343 filed Sep. 22, 2011 and U.S. Provisional Patent Application Ser. No. 61/626,787 filed Oct. 3, 2011 (the entire disclosures of each of the foregoing patent applications and patent are fully incorporated herein by reference as if fully set forth herein).
[0042] Further very specific embodiments of the inventive method are beneficially practiced when a performer's performance is subject to a regulation. Examples of such performances include, without limitation, those performances subject to the federal record-keeping requirements set forth in 18 U.S.C. §2257, 18 U.S.C. §2257A etc., and related regulations set forth in 28 C.F.R. Part 75 et seq. (“2257 Regulations”). In some embodiments, compliance with the federal record-keeping requirement according to a method set forth in U.S. Pat. No. 8,027,929 is carried out prior to, or materially contemporaneously with, the production or transmission of a performance, or portion of a performance, that is subject to the federal record-keeping requirement, as described in the referenced patent.
[0043] For example, if the performer herself establishes an aggregation link to the aggregate site (i.e., self-populates the aggregation site), thus making her performance, or part thereof, visible on additional sites (such as one or more aggregate sites), she may be considered the distributor or producer of her performance as provided by 2257 Regulations with respect to the performance content make visible at such aggregate site(s). To comply with the 2257 Regulations, a producer of live performance content that is subject to the 2257 Regulations (such as live performance content containing sexually explicit depictions) must affix or associate a compliance statement as specified by the 2257 with the subject content and the producer must update the producers records which are required to be maintained pursuant to the 2257 Records to reflect the creation and distribution of the subject performance content (e.g., by addition of the URL(s) of the aggregate site at which the live subject content is displayed, a unique identifier of the performance, date of production, copy of the depiction, etc., to the records maintained by the producer of the live performances subject to the 2257 Regulations). Thus, in some preferred embodiments, when the performer self-populates the aggregation site with an aggregation link to her performance, she also triggers the functionality of an automatic §2257 compliance system that updates a record system and provides an appropriate compliance statement that is displayed at the aggregation site(s), in accordance with the methods disclosed in U.S. Pat. No. 8,027,929. | A method of aggregating displays of performances into an aggregate site on a network is provided. The aggregated performances originate from at least one performance site on a network. The method includes the steps of selecting a performance criterion; observing at least one performance originating from at least one performance site on a network, the performance being associated with a link; determining when at least one performance meets the performance criterion; establishing an aggregation link to the link associated with the performance meeting the performance criterion; and providing the aggregation link to an aggregate site on a network such that the performance is accessible on the aggregate site. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to the application having the Ser. No. 653,680 entitled A DOUBLE-VELOUR SYNTHETIC VASCULAR GRAFT AND PROCESS OF MANUFACTURING SAME, filed Jan. 29, 1976, and which issued as U.S. Pat. No. 4,047,252 said application being assigned to the same assignee as the present application, and Ser. No. 638,580 entitled CIRCULARLY-CRIMPED TUBULAR PROSTHESIS AND METHOD OF PRODUCING SAME, filed Dec. 8, 1975 and now abandoned. This latter application is also assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
In the process of vascular surgery it frequently becomes necessary to replace or bypass a defective vein or artery or portions thereof. A wide variety of materials have been examined and tested as grafts. Examples are bovine and porcine blood vessels, and tubular prosthesis woven or knitted to Teflon and other synthetic fibers.
Blood vessels taken from umbilical cords have recently been disclosed as being highly effective as grafts as well as for other prosthetic applications in that they appear to be completely free of thrombogenicity and antigenicity. However, the umbilical cord vessels are of relatively small diameter, so that tubular prosthesis of these vessels have a maximum internal diameter of about 5 mm. For larger vessels such as the aorta and the aorta in combination with the two iliac arteries, knitted tubular prostheses are best from the standpoint of tissue ingrowth and freedom from thrombogenicity. Furthermore, polyester fiber, and, in particular, polyester fiber manufactured by Dupont and sold under the tradename of Dacron (polyethylene terephthalate appears to be the best fiber.
A number of problems arise in connection with the knitted tubular prostheses. The first problem is that of leakage of blood through the wall of the prosthesis. This problem is met by making the openings in the knitted wall as small as possible and by preclotting the blood of the patient in the wall of the prosthesis. Optimally, all openings in the wall of the prosthesis are closed with clotted blood prior to joining the prosthesis to the vessels of the patient by anastomosis.
In order that the graft should be essentially circular in section, thereby providing for minimum resistance to flow of blood therethrough, it is necessary that the prosthesis be crimped. Sprial crimping which provides an appropriate degree of rigidity to the tubular prosthesis has been disclosed in U.S. Pat. No. 3,945,052 issued Mar. 23, 1976. Circular crimping which provides additional protection against twisting is taught in application Ser. No. 638,580 referred to above.
Once the graft is inserted and the patient is closed up, success of the graft depends upon ingrowth of tissue through the wall of the prosthesis to form an interior which will resemble the vessels into which the graft has been inserted insofar as it serves to provide a lumen for the flow of blood therethrough without causing either thrombosis or rejection.
It has been found that the ingrowth of tissue is facilitated by "roughening" both the interior and the exterior of the tubular prosthesis. Sauvage in German Offenlegungsschrift No. 24 61 370 has disclosed a prosthesis which is circularly knitted and which has a pile velour both interior and exterior to the wall of the prosthesis. Further, the prosthesis crimped, though in an irregular fashion, so that the rigidity of the prosthesis varies along its length.
Sauvage's prosthesis is knitted of at least three threads and preferably four, all of the threads forming portions of the wall, one thread, periodically, being drawn into exterior loops and another thread, also periodically, being drawn into interior loops. As is evident, where one or two threads are used exclusively to form the wall of the prosthesis and the other two threads are used, at least in part, for forming the wall of the prosthesis, the wall of the prosthesis is necessarily relatively thick. Further, the number of loops, both interior and exterior per unit area cannot be maximal since the looped threads are also used for forming the wall of the prosthesis. Since the loops have been found to facilitate the growth of tissue in the prosthesis wall, it is evident that it would be desirable that the number of loops per unit area of wall be as large as possible.
As can be seen, then, it would be desirable that a number of improvements be introduced into the construction of knitted fabric prosthesis, these improvements including smaller openings between the threads, greater number of loops per unit area, thinner fabric taking into account both the wall thickness and the height of the interior and exterior loops, the reduction in thickness to be achieved without increase in porosity or loss of rigidity, and more rapid ingrowth of tissue.
SUMMARY OF THE INVENTION
One or more elongated strips of fabric are warp-knitted using a single thread to form what is termed the "wall" or "trellis" of the fabric and a second thread which passes back and forth through the wall to form loops on both faces of the fabric. These loops constitute a velour or pile and the fabric having loops on both faces thereof is termed a double-velour fabric. The fabric may be used directly as a prosthesis or two such strips are joined together along the edges thereof to form a fabric of tubular structure. The fabric is then crimped, preferably circularly-crimped to provide the desired degree of rigidity. Uniform crimping of the fabric provides uniform rigidity and uniform resistance to kinking.
Preferably, the wall of the fabric is formed of a single thread which may be single-ply, double-ply or multiple-ply. The thread consists of filaments which are first twisted together to form strands. The term "ply" then refers to the number of strands twisted together to form the thread. A single-ply thread, for example, is a single strand thread, and a multiple ply thread has more than two strands. The total count of the thread of the trellis is between about 30 and about 100 denier, and the thread is preferably non-texturized. The total count of the thread forming the pile is between about 30 and about 150 denier and is preferably texturized.
The preferred thread is synthetic polyester and the preferred polyester is that manufactured by Dupont under the tradename of Dacron (polyethylene terephthalate).
To manufacture the pile, the thread forming the pile is fed to the knitting machine at a rate greater than that at which the thread forming the wall is fed. The ratio of the feed rate of the thread for the pile to the feed rate of the thread for the trellis is between 2.2:1 and 1.2:1.
The thread forming the pile passes through the trellis in both directions so that the loops on one face of the trellis are continuous with the loops on the other face of the trellis. Where the prosthesis is tubular, the loops on the exterior (termed the "technical face") of the trellis are continuous with the loops on the interior of the trellis and the ratio of the exterior to interior loops lengths preferably lies between 3:1 and 1:1. The loops on the interior (termed the "technical back") of a tubular prosthesis are formed from the pile underlap and may be termed sub-loose because they are formed in pairs as the result of the presence of a trellis underlap on the interior surface which divides each interior loop (i.e. pile underlap) in two.
Warp-knitting using a flat thread for the trellis and a texturized thread for the loops makes it possible to provide a prosthesis with smaller openings, that is, lower porosity than is the case with circular knitting, and with loops which are continuous from one face of the prosthesis to the other, thereby facilitating growth of tissue through the wall of the prosthesis. Also, where the prosthesis is tubular, greater rigidity is provided for a given thickness of the prosthesis.
The pile is made with an open stitch while the trellis is made with a closed stitch. Also, the underlapping of pile and trellis threads is in opposite directions.
Accordingly, an object of the present invention is a prosthesis having finer openings than hitherto available, with pile loops on both surfaces of said prosthesis and with a degree of rigidity greater than available with a circular-knitted prosthesis of the same thickness.
Another object of the present invention is a warp-knitted prosthesis which can readily be formed into a tubular structure, both straight and bifurcated.
A further object of the present invention is a warp-knitted prosthesis which facilitates growth of tissue from one face thereof to the other.
Yet another object of the present invention is a warp-knitted prosthesis of the double-velour type in which the trellis thread is in closed stitch and the underlaps are in opposed directions.
An important object of the present invention is a method of warp-knitting a prosthesis wherein a single thread which may have a plurality of plies forms the wall or trellis of said prosthesis and another thread which also may have a plurality of plies passes from one face of said prosthesis to the other thereby making the fabric of said prosthesis a double velour.
A significant object of the present invention is a method of forming a tubular prosthesis of the double-velour type wherein said prosthesis may be bifurcated or straight and said prosthesis has uniform rigidity along each of its limbs.
A vital object of the present invention is a method of forming a double-velour prosthesis wherein the height of the pile on both faces of the prosthesis fabric may be controlled by controlling the ratio of the rate of feed of the thread forming the fabric.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the product possessing the features, properties, and the relation of components which will be exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1a is a schematic diagram of a warp-knitting machine being fed with thread from four beams and knitting two elongated strips of double-velour fabric for use in a prosthesis;
FIG. 1b is a view taken along line 1b--1b of FIG. 1a;
FIG. 1c is a view taken along line 1c--1c of FIG. 1a;
FIG. 2 is a view from the interior of a double-velour fabric showing the relative position of the threads forming the fabric;
FIG. 3 is a point diagram of the fabric of FIG. 2;
FIG. 4 is a view along line 4--4 of FIG. 2; and
FIG. 5 is a perspective view of a circularly-crimped bifurcated prosthesis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a warp-knitting machine is represented generally by the reference numeral 11. The machine 11 is being fed with threads 12, 13, 14 and 15, respectively, from spools 17, 18, 19 and 21. Machine 11 as shown in FIG. 1 is simultaneously warp-knitting two elongated strips of fabric 22 and 23. The fabric is carried forward by a conveyor belt (not shown). Threads 12 and 13 are processed by machine 11 into fabric strip 22 and threads 14 and 15 are similarly processed into fabric strip 23. Threads 12 through 15 are preferably of polyester and best results have been achieved where the polyester is of Dacron, manufactured by Dupont Company.
In a preferred form, one thread of each pair is flat and is knitted by machine 11 to form the wall or trellis of the fabric. The other thread of each pair preferably texturized and is passed back and forth through the wall of the fabric strip to form pile loops on both sides of the trellis of the fabric. The loops on both sides of the fabric are therefore continuous with each other. The feed rate of the thread which forms the loops is greater than the feed rate of the thread which forms the trellis of the fabric. The ratio of the feed rate of the loop thread to the trellis thread preferably lies between 2.2:1 and 1.2:1. As is evident, the ratio of the length of loops thread in the fabric to trellis thread in the fabric must also lie between 2.2:1 and 1.2:1. The pile may also be referred to as pile velour.
Threads 12 through 15 may be single-ply, double-ply or multi-ply. Preferably, the total count for the trellis thread, whether of one or more plies, is between about 30 and about 100 denier and of the velour thread is between about 30 and about 150 denier.
In the knitting operation the number of needles per inch is from about 18 to about 36 with the preferred number being 28/inch. The fabric, prior to compaction has 35 to 70 courses and 20 to 38 wales per inch. After compaction, the number of courses is from 50 to 100 per inch and the number of wales is 30 to 60 per inch. The fabric may be knitted as a tricot or as locknit (reverse jersey).
Depending upon the vessel which is to be reinforced by a prosthesis in accordance with the present invention, or replaced or by-passed by such a prosthesis, there are applications in which a relatively light fabric is desirable and other applications in which a relatively thick fabric is desirable. For the light fabric, a single ply with a count of about 40 denier is preferred. Such a thread should consists of from 25 to 29 filaments. For the heavy fabric a double-ply thread having a total count of about 80 denier is preferred. Such a thread preferably has 50 to 58 filaments therein. As is evident, fabrics with a single or multi-ply thread having counts anywhere from 30 to 150 denier may be found useful for specific applications.
In knitting the fabric of the present invention the trellis, indicated by the reference numeral 26, is knitted with a closed stitch whereas the loops 27 are knitted with an open stitch. The point diagram for the wrap-knitted fabric of FIG. 2 is shown in FIG. 3. As can be seen, the trellis 26 is knitted with a closed stitch while the loops forming the velour 27 are knitted with an open stitch.
Returning to FIG. 2, that portion of the trellis thread indicated by the reference numeral 28 is a trellis underlap with reference to that portion of the pile thread underlap 29 which passes over it (remembering that FIG. 2 is a view of the fabric from the inside thereof). The loop which would be formed by thread underlap 29 is bisected by trellis underlap 28 so that the loop is cut into two sub-loops 29a and 29b as shown in FIG. 4. Underlap 28 dominates because it is relatively tight whereas underlap 29 is loose as the result of the feed ratio being greater than 1. As a result, there are two loops on one face of the fabric, here the interior thereof, for each loop on the exterior of the fabric.
As is evident, underlaps 28 and 29 are in opposite directions. It is possible to form a double velour with the underlaps in the same direction, but as can be seen, the pile loops would not be cut in two so that the number of loops on the inside would be the same as that on the outside of the trellis. The hand of such a product is rather different from that of a product made with opposed underlaps but is useful for certain purposes.
The overlap having the reference numeral 31 is shown in FIG. 2 as lying along the trellis, but this representation is schematic only. Loops 31 are shown more accurately in FIG. 4 as extending outwardly from trellis 32.
A major factor in the warp-knit fabric disclosed herein is the difference in the type of stitch used for making the trellis and the pile. The trellis is made with a closed stitch whereas the pile is made with an open stitch. This difference in the type of stitch used provides for the rigidity of the structure whereas the open stitch of the pile provides lower porosity in the structure, more uniform pile, more even appearance and better hand.
By control of warp-knitting machine 11 the ratio of the height of loops 31 to sub-loops 29a and 29b can be controlled. Preferably this range lies between 3:1 and 1:1. The fact that these loops, exterior and interior are continuous with each other facilitates the ingrowth of tissue from the exterior of a tubular prosthesis to the interior thereof and accelerates the conversion of the surface of the prosthesis to one resembling the interior of a normal artery or vein. Also, the interior and exterior loops provide excellent anchorage for the tissue which deposits. It is these properties which are primarily responsible for the excellent results achieved with the double-velour warp-knitted fabric of the present invention.
To warp-knit a tubular prosthesis, threads 12 and 13 are combined to form back strip 22 and threads 14 and 15 are combined to form front strip 23. As the strips 22 and 23 are warp-knit by machine 11, the machine simultaneously knits the two strips together along the elongated edges thereof, the joins between the two strips being indicated by the reference numeral 24. The machine can knit a bifurcated section indicated by the reference numeral 25a. Generally, it is desirable to reinforce the crotch 25b where the bifurcated section 25a joins tubular section 25c. The reinforcement is carried out subsequent to the knitting and is sewn. The joined strips are then brought into essentially cylindrical form and crimped. As aforenoted, it is highly desirable that the crimping be uniform so that the rigidity along the prosthesis is constant. Further, it is also strongly desirable that the crimping be shallow, thereby facilitating shaping of the ends of the prosthesis to conform to openings in vessels to which the prosthesis is to be joined.
The crimping may be done in spiral fashion but preferably is circular, since circularly crimped tubular prostheses are free of any tendency to twist when extended. Such twist can increase the danger of kinking. Avoidance of twist during stretching of the prosthesis as is frequently necessary during attachment to other vessels is further facilitated by the use of one or more guidelines 33 as shown in the bifurcated prosthesis 34 in FIG. 5.
The use of the flat thread for the trellis makes it possible to produce a fabric of lower porosity. The use of texturized thread for the velour loops helps to decrease the porosity of the resultant fabric and simultaneously provide better anchorage for tissue during ingrowth. The combination of the two types of thread, a combination which, so far, has not been achieved with any other type of knitting, yields a fabric and tubular prosthesis with an extremely fine hand with appropriate rigidity over a wide range of thicknesses and which conforms excellently after shallow and uniform crimping to the openings in the vessels to which the prosthesis is to be joined. As an example of the range of thicknesses which can readily be provided, the thicknesses being measured before crimping, fabrics ranging from about 0.40 up to about 0.80 mm in thickness can be made on a routine basis. This range is to be regarded as merely exemplary-fabrics of either smaller or greater thickness can undoubtedly be manufactured by the process as described.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above process and in the product set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween. | A warp-knitted fabric has pile loops on both faces thereof. The loops on both faces are continuous with each other so that when the fabric is used as a prosthesis, growth of tissue from one face to the other is facilitated. This feature is particularly significant when the fabric is fashioned into tubular form, whether straight or bifurcated. The structure of the fabric is such that a desired degree of rigidity is obtained with a thinner fabric than has hitherto been the case. | 3 |
FIELD OF THE INVENTION
The present invention relates to aquatic sports devices known as kneeboards and skiboards for supporting a user towed behind a boat.
BACKGROUND OF THE INVENTION
Other than water skis, two of the most popular types of water sports devices are skiboards and kneeboards. A skiboard is used like a slalom water ski, but is more similar in outline shape to a narrow surfboard and has foot straps or bindings secured to the upper surface of the board. The user rides the board upright while being towed. See, for example, co-pending U.S. patent application Ser. No. 07/810,817, filed Dec. 19, 1991, titled "Water Skiboard With Rotatable Binding," which is expressly incorporated by reference herein.
Known kneeboards are wider and shorter than skiboards. Rather than supporting a user upright, a kneeboard typically has a resilient pad secured to the upper surface of a baseboard with side-by-side recesses shaped to receive the user's knees and shins. The user rides the kneeboard in a low kneeling position. An adjustable strap is provided for bearing against the top of the user's thighs to hold the user in position while hanging on to a tow rope.
Kneeboards and skiboards currently available are distinct products so that a consumer must choose between the two or purchase both.
SUMMARY OF THE INVENTION
The present invention provides a water sports device including an elongated baseboard having the approximate outline shape of a kneeboard, one or more foot-restraining members releasably attachable to the board for configuring it to be used like a skiboard, and a kneepad and associated thigh strap releasably attachable to the board for configuring it for use as a kneeboard. In the preferred embodiment, the board includes a central track extending lengthwise of the baseboard and adapted to receive fasteners projecting from the kneepad or, with the kneepad removed, fasteners projecting from the foot-restraining members.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a top perspective of a water sports board in accordance with the present invention with parts shown in exploded relationship;
FIG. 2 is a top perspective of the board of FIG. 1 configured as a kneeboard;
FIG. 3 is an enlarged fragmentary transverse vertical section along line 3--3 of FIG. 2;
FIG. 4 is an enlarged fragmentary transverse vertical section along line 4--4 of FIG. 2;
FIG. 5 is a further enlarged fragmentary perspective of a portion of a water sports board in accordance with the present invention illustrating mechanism for fastening a knee pad in position on the board, with parts shown in exploded relationship;
FIG. 6 (on the drawing sheet with FIG. 2) is a top perspective of a water sports board in accordance with the present invention configured as a skiboard; and
FIG. 7 (on the drawing sheet with FIGS. 3 and 4) is an enlarged transverse vertical section of a water sports board in accordance with the present invention configured as a kneeboard illustrating mechanism for fastening a foot-restraining member in position on the board.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the water sports device in accordance with the present invention includes an elongated water-skimming baseboard 1 having an outline shape approximately the same as a conventional kneeboard. Board 1 can be a plastic laminate having a polyethylene outer surface and rigid polyurethane core similar to conventional water sports boards. Preferably the upper surface of the baseboard has an upward-projecting ridge 2 defining a wide oblong top recess 3 having a substantially planar bottom. Recess 3 preferably encompasses the major portion of the width of the board and at least about one-half the length of the board.
A knee pad 4 is detachably connectible to the upper surface of the board for configuring the board as a kneeboard; or, with the pad removed, foot-restraining members such as straps or bindings 5 are detachably connectible to the upper surface of the board so that it can be used like a skiboard. In either case, the pad or foot-restraining members have fasteners that cooperate with fastening mechanism of the board to achieve the desired disconnectable coupling.
In the illustrated embodiment, the baseboard includes a longitudinally extending channel 6 centered in the recess 3. Channel 6 is of inverted T shape with the stem of the T opening through the upper surface of the recessed area of the board. A short, wider opening 7 into the base of the channel is located approximately centrally between the ends of the channel.
Preferably knee pad 4 includes a rigid or substantially rigid baseplate 8 having a planar bottom. The baseplate has the same outline shape as the oblong board recess 3 for close fitting of the baseplate in the recess as shown in FIG. 2. An upper resilient cushion 9 with the usual knee and shin recesses 10 is secured to the baseplate.
In the preferred embodiment shown in the drawings, the composite knee pad 4 has a rear stationary fastener 11 and a front rotatable fastener 12. As shown in FIG. 3, the rear stationary fastener 11 includes a bottom T nut 13 with an enlarged head insertable downward through the channel opening 7 (FIG. 1) when the knee pad 4 is centered on the board but offset forward relative to the recess 3. From such position the knee pad 4 is slidable lengthwise rearward such that head of the T nut of fastener 11 is received in the rear portion of the channel 6 to prevent substantial upward movement of the rear part of the knee pad relative to the board 1, as seen in FIG. 3.
The construction of the rotatable front fastener 12 is shown in FIG. 4 and FIG. 5. The front fastener includes a top knob countersunk in the cushion 9 of the knee pad. The knob has a stubby handle portion 14 projecting upward from a disk 15. A threaded shank 16 projects downward from the disk through a top washer 17, a resilient snubber O-ring 18, a bottom washer 19 and a hole 20 through the baseplate 8 of the knee pad adjacent to the leading end portion of the pad and centered between the knee and shin recesses 10. A modified T nut 21 having wings 22 that are beveled or tapered oppositely is secured to the bottom of the shank 16 below the baseplate 8.
FIG. 5 illustrates the orientation of the front T nut 21 with its wings 22 extending longitudinally of the channel 6 such that the wings can pass downward into the base of the channel. The T nut includes an upper hub 23 of a diameter less than the width of the top opening of the channel and fixed on the shank 16. Turning of the handle 14 in a tightening direction, clockwise as viewed in FIG. 5, rotates the wings into the undercut portions of the channel. Due to the beveling of the top surfaces of the wings, first a vertically thin section of each wing is hooked under the inward-extending top flanges 24 of the channel, and then progressively thicker portions of the wings engage the undersides of the flanges so that the T nut is wedged downward as it is turned in the tightening direction. The effect is to clamp the snubber O-ring 18 between the washers 17 and 19 until the O-ring is substantially fully compressed and the wings extend perpendicular to the length of the channel as shown in FIG. 4. In such position, the knee pad is firmly affixed to the upper surface of the board in the condition illustrated in FIG. 2, but is quickly and easily disconnectible from the board by turning the forward rotatable fastener 12 so as to position the wings of the T nut extending longitudinally of the channel, whereupon the front of the knee pad can be raised and the pad assembly can be slid forward until the rear fastener registers with the wider channel opening 7 shown in FIG. 1.
Returning to FIG. 2, to complete the configuration of the preferred water sports board in accordance with the present invention as a kneeboard, a thigh strap 25 is secured to the board by inverted U-shaped cleats 26 positioned at opposite sides of the pad-receiving recess of the board. Such cleats form eyes 27 opening transversely of the length of the board. Strap 25 has a rectangular ring 28 at one end. The free end of the strap is first threaded through the eye of one cleat and through the ring 28 at the other end of the strap and then is threaded through the other cleat from the inside. The free end portion of the strap is folded back over itself and over the user's thighs. Preferably the free end portion 29 and central portion 30 of the strap have cooperating strips of hook and pile fastening materials for infinite adjustment of the tightness of the strap over the thighs of a user.
The water sports board in accordance with the present invention also can be configured for use as a skiboard. First, strap 25 is removed by unthreading it from the cleats 26. The cleats themselves preferably are attached to the board by screws having exposed heads such that the cleats also can be removed. The knee pad is detachable as described above. The foot-restraining members can be coupled to the board in the recess 3 close to the waterline, unlike known skiboards in which the foot-restraining members are mounted over the highest surface. Preferably the foot-restraining members are bindings 5 that have rotatable mountings of the type described in co-pending U.S. patent application Ser. No. 07/810,817 referenced above. Each binding includes a circular mounting member 31 on which the remainder of the binding is rotatably mounted. As seen in FIG. 7, the mounting member 31 can be secured to the board by fasteners in the form of T nuts 32 having enlarged heads received in the base of the channel 6 and screws 33 which can be tightened to clamp the circular mounting members 31 to the upper surface of the board 1. The device in accordance with the present invention then is ready for use as a skiboard with a user in upright position, but the board can be reconfigured as a kneeboard quickly and easily.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A water sports device including an elongated baseboard having the approximate outline shape of a kneeboard, one or more foot-restraining members releasably attachable to the board for configuring it to be used as a skiboard, and a kneepad and associated thigh strap releasably attachable to the board for configuring it for use as a kneeboard. | 1 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method and apparatus for providing purified ice pieces and purified liquid water from a source of unpurified liquid water. More particularly, the present invention relates to a method and apparatus for producing and maintaining predetermined amounts of purified ice and purified liquid water in a common appliance housing.
2. Discussion of the Prior Art
In recent years there has been considerable public concern about the poor quality of tap water. Excessive chlorination, contamination by pesticides, and a variety of other factors have contributed to this concern. As a consequence, sales of bottled water and faucet filters have increased dramatically. Over the long run both of these solutions are expensive. It is desirable, therefore, to provide a low cost alternative to providing purified drinking water for the home and workplace. An attempt to provide purified water for household use by means of a freezing technique is disclosed in U.S. Pat. No. 3,338,065 (Ashley). In that patent there is a disclosure of an elongated freezing element disposed at the bottom of a tank of unpurified water. Water adjacent the surface of the freezing element freezes on that surface and accumulates as an ice mass until the freezing element is defrosted. The ice mass is released from the defrosted freezer element and floats to the top of the tank where it melts. Without stating how, the patent presumes that the formed ice mass is free of impurities present in the unpurified water; however, experience dictates that this modified static freezing approach does not significantly eliminate entrapment of impurities in the formed ice mass. The Ashley patent also states that the released ice mass is "washed" by the body of water as the mass floats upwardly in the tank toward the surface; however, this "washing" action, at best, removes impurities only from the surface and does not remove impurities trapped in the ice mass. The liquid at the top of the tank, where the ice masses melt, is described in the patent as being purified and, since it is less dense than the unpurified water in the tank, remains at the top of the tank without significantly mixing with the unpurified water. Water from the top of the tank may then be withdrawn for consumption. To the extent that this process purifies water, it is believed that the purification is minimal.
Similarly, the sale of purified ice cubes has increased significantly because of concern over impurities in ice cubes formed from unpurified tap water. Typically, when ice is made from tap water, the water is poured from the tap into compartments of trays where the water remains stationary as it freezes. This static process of freezing tap water whole, or in bulk, results in all of the original tap water impurities, including dissolved gases, remaining trapped in the ice cubes. In other words, the impurities are not chemically dissolved in the frozen water; rather, they are mechanically trapped in the resulting solidified ice cube structure. The resulting cubes are cloudy, as opposed to the clear appearance of purified ice, and are porous such that they tend to absorb odors from the refrigerator and freezer. Even if those commercial refrigerator-freezers that have a built-in automatic icemaking feature, the original water source is tap water, and the tap water is frozen in bulk. Consequently, the resulting ice cubes contain the trapped tap water impurities and are also porous in texture.
It is known in the prior art that unpurified liquid water may be issued forcibly against a surface that is cold enough to cause progressive accumulation of a mass of ice thereon. The stream of water, flowing over the growing ice mass, washes away impurities in the water before the impurities can be trapped in the ice mass. Systems using this flowing or dynamic freezing technique are disclosed in U.S. Pat. Nos. 2,341,721 (Whitney), and 3,170,779 (Karnofsky). Generally, these systems are directed to large scale freezing and purifying operations that are not suitable for producing relatively small ice pieces (i.e., pieces the size of ice cubes as used in drinks). If the known dynamic freezing process were employed in a household refrigerator, therefore, it would be necessary to break the resulting ice mass into small pieces suitable for use in drinks; the prior art does not address the problem. Further, the dynamic freezing technique has generally required an ice making machine made specifically for that purpose and not as an adaption to a household refrigerator. A separate icemaking machine using the dynamic freezing process would be expensive and not practical for most consumer applications.
SUMMARY OF THE INVENTION
In accordance with the present invention, the above-described dynamic freezing technique is employed in a manner to form multiple individual purified ice pieces. This ice is periodically collected in a bin, the bottom of which is selectively heated to melt the ice and obtain purified liquid water that is drained off into a separate container from which it may be dispensed. By combining both ice making and purified liquid water formation in the same unit, the resulting cost of the unit becomes feasible as compared to the continuing cost of purchasing purified ice and purified liquid water on a retail basis. Heating of the ice bin is automatically controlled to maintain the desired amount of purified liquid water in the container. Similarly, a refrigerant vapor compression system, employed to provide cooling for ice formation, is automatically controlled to maintain a prescribed amount of ice in the bin and to operate in synchronism with bin heating for melting the ice.
The dynamic freezing technique is adapted to form ice by passing a stream of unpurified water over one surface of a plate at which selected areas are cooled to below the freezing temperature of water by contacting the opposite surface of the plate with respective sections of evaporator tubing. Periodic heating of the selected areas permits the accumulated ice to detach from the plate and be collected in the bin.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and many of the attendant advantages of the present invention will be appreciated more readily as they become better understood from a reading of the following description considered in connection with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference characters, and wherein:
FIG. 1 is a schematic flow diagram of a system constituting one embodiment of the present invention;
FIG. 2 is a schematic flow diagram of a modified portion of the system of the FIG. 1;
FIG. 3 is a schematic flow diagram of a second embodiment of the system of the present invention;
FIG. 4 is a schematic flow diagram of still another embodiment of the system of the present invention;
FIG. 5 is a schematic flow diagram of a modified portion of the system illustrated in FIG. 4;
FIG. 6 is a schematic flow diagram of still another system embodiment of the present invention;
FIG. 7 is a schematic diagram of a modification suitable for use in any of the system embodiments described herein; and
FIG. 8 is a schematic diagram of a modification useful in any of the system embodiments described and illustrated herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the accompanying drawings, an ice maker includes an evaporator tube 2 contacting the dry or control surface of a vertical ice-forming plate 3 at multiple spaced points. For some applications a plurality of such plates may be employed. Unpurified water discharged as a jet or stream from nozzle 4 flows down the wet or ice-forming surface of plate 3, whereby ice pieces 5, 6, 7 and 8 are formed at spaced areas corresponding to the locations of contact between evaporator tube 2 and plate 3. Refrigerant vapor from the evaporator flows back to a compressor 9 where it is compressed and then flows to an air-cooled condenser 10. Condensed liquid refrigerant flows via liquid line 11 to a metering device 12, typically an expansion valve, then back to evaporator 2 in a conventional closed circuit refrigeration flow path. Excess water flowing over the growing ice pieces 5, 6, 7 and 8 carries away impurities before they can be trapped and then drains into sump 13. Water from sump 13 is drawn by pump 14 and pumped back to nozzle 4 to form a continuous circuit of unpurified water flow.
After a predetermined time has elapsed for ice pieces 5, 6, 7 and 8 to grow to adequate size, a harvest of the ice pieces is initiated. A cam 15a of a timer 15 actuates switch points 15b to break an energizing circuit for pump 14. With pump 14 deactuated, water in transit from pump 14 to nozzle 4, and water flowing over the ice pieces, flows back to raise the level in sump 13. This activates a siphon 16 which then dumps the remainder of the water from sump 13 to the drain. At the same time, timer 15 activates switch point 15b to deactivate pump 14, and activates switch point 15c to energize a hot gas valve 17, allowing hot refrigerant gas to be shunted around the condenser and expansion valve and flow directly into evaporator 2. The warming effect of this hot gas detaches the ice pieces from plate 3 and permitting the pieces to fall into ice bin 18. Meanwhile, the water in sump 13 is replenished by tap water from pipe 19 under the control of a float valve 20. After a predetermined ice piece harvest interval, cam 15a of timer 15 reverses the settings of the switch points, de-energizes hot gas valve 17, and reactivates pump 14 so that ice making can be resumed. A repetitive cycle of harvest and ice making is thus continued until ice bin 18 is full, at which time the ice pieces come into contact with the ice quantity sensor of bin switch 21 which opens, causing compressor 9 to be de-actuated. The ice pieces thusly collected, because they are continuously washed by the stream evacuating from nozzle 4 as they are being formed, have a much higher purity then that of the original tap water. The ice-making apparatus so far described is of a type commonly used and well known. Similarly, any other type of icemaker using a recirculating flow of pumped water, and thus being capable of producing a supply of pure ice pieces, can be used in this invention.
Any ice which melts in bin 18 drains through a pipe 22, having its inlet at the bottom of the bin, into a bottle 23 or other container which rests on a platform 24 hinged at a positionally fixed point 25. By "positionally fixed" it is meant that the hinge or pivot point 25 is stationary relative to the common cabinet or housing for all of the components described herein. If bottle 23 is less than full, its weight is overcome by the resilient bias force of a balance spring 26 which pulls platform 24 counter-clockwise (as viewed in the drawing) to swing the platform upwardly. This upward movement causes an upward movement of control link 27 connected to platform 24 at connecting pivot 28, the latter being movable relative to the common system housing. Upward movement of control link 27 causes counter-clockwise rotation of a rocker arm 29 about a fixed pivot point 30 to which it is connected at a movable pivot point 31. The rotation of rocker arm 29 causes an override switch 32 to close, thereby bypassing bin switch 21 and permitting compressor 9 to run regardless of the state of the bin switch. Rotation of rocker arm 29 also permits switch 33 to close and thus activate a melting fan 34 which draws air from a plenum 35. A condenser fan 36 forces ambient air about the outside of condenser 10, where the air is warmed, and then into the plenum 35. Fan 34 forces this warm air to flow through a duct 37, over heat exchange fins 38 or other surfaces in duct 37 in contact with the underside of bin 18, and then through discharge duct 39 back to the ambient environment. Ice resting on the bottom of bin 18 is thus melted at a relatively fast rate and the resulting water is drained via pipe 22 into bottle container 23.
As ice melts at the bottom of the bin, the weight of the ice pieces in the bin causes more ice pieces to continually move downwardly to the bin bottom. Meanwhile, the ice-making function continues so that a supply of fresh ice pieces is collected in the bin. When container 23 is full, its weight overcomes the bias force of balance spring 26 and causes platform 24 to drop (i.e., pivot clockwise about fixed pivot 25). Control link 27 is thereby pulled downwardly, rotating rocker arm 29 clockwise to open switch 33 and shut off melting fan 34. Override switch 32 also opens and leaves control of ice making to bin switch 21. With melting fan 34 shut down, melting of ice pieces at the bottom of the bin ceases. However, after some hours without withdrawal of water from container 23, some slight additional unintended melting of ice occurs in bin 18 causing a small overflow from container 23. Trough 40 catches this overflow which drains from the system housing through pipe 21 to a drain.
Balance dampers 42 and 43 are forced open by air flow when melting fan 34 is in operation, but are biased to close when the air flow ceases. These dampers prevent inadvertent air drafts through heat exchange fins 38 which would cause undesired melting of the ice pieces. When the ice maker is making ice pieces, bu is not in the melting mode (i.e., the melting fan 34 not running), air from condenser fan 36 is forced through condenser 10 into plenum 35 but does not flow through de-actuated fan 34; instead, the air exits plenum 35 through opening 45 and flows back to the ambient environment.
The override switch 32 is employed to cause the ice-making process to be in operation at any time the ice melting function is employed. This is an advantage since ice pieces are needed to replace the ice pieces that are melted. It should be noted, however, that this feature is not essential and a slightly simpler arrangement results if switch 32 is eliminated. Under such circumstances, if melting is started with a full ice bin, ice making is not commenced until the melting function drops the level of ice pieces in the bin 18, at which time the bin switch 21 initiates the ice making process. The melting process without continued ice making process is somewhat slower than with continued ice making since there is no heating effect from condenser 10. However, ambient air flowing into plenum 35 through opening 45 supplements the reduced air flow through condenser 10 without condenser fan 36 running and significant melting does occur, albeit at a slower rate.
FIG. 2 illustrates a modification in which the air flowing to melting fan 34 is independent of the condenser 46 which, in this modification, can be either a water-cooled or an air-cooled condenser. Ambient air is conducted to fan 34 via duct 47. Ambient air is not quite as warm as condenser-heated air, but in sufficient quantity it accomplishes the melting function.
The embodiment illustrated in FIG. 3 employs a single fan 48 for both the melting and heating functions effected by melting fan 34 and condenser fan 36 of FIG. 1. When an ice making operation is underway, but the melting mode is not activated, fan 48, mounted in plenum 49, draws ambient air through condenser 10 and discharges it back to the ambient environment through duct 50. However, when container 23 is less than full, as already described in relation to FIG. 1, control link 27 is caused to move upwardly to rotate rocker arm 29 counter-clockwise and actuate override switch 32. Diverter damper 51 rotates about fixed pivot 52 under the impetus of a control arm 53 linked by a connecting rod 54 to connecting pivot 31. When rocker arm 29 rotates counter-clockwise, t causes diverter damper 51 to open so that the air discharged from fan 48 flows through duct 37 instead of to the ambient environment. This air flow through duct 37 achieves the melting function in the same manner described in relation to FIG. 1. All other system functions in the FIG. 3 embodiment are the same as described in relation to FIG. 1.
FIG. 4 illustrates a water cooled embodiment of the invention. The ice making function is the same as in the FIG. 1 embodiment, but the system condenser 54 is water cooled with a water valve 55 controlling water flow. When container 23 is less than full, control link 27 moves upwardly, as previously described, to cause rocker arm 29 to rotate counter-clockwise and actuate override switch 32. Warm water flowing from condenser 54, through pipe 56, flows into flexible tube 57 which is anchored to the housing on block 58. Connected to rocker arm 29 is a link 59 attached to a ring 60 which encircles flexible tube 57, so that when rocker arm 29 rotates to activate override switch 32, the outlet of flexible tube 57 is moved to a position above a sump 61. Warm water thus flows into sump 61 and drains through pipe 62. Pipe 62 makes contact with the bottom of ice bin 18 so that the warm water flow melts ice pieces at the bottom of the bin. Drain pipe 63 discharges the water to the drain. When container 23 is full, its weight causes rocker arm 29 to reverse its rotation so that link 59 pulls the outlet of flexible tube 57 over sump 64. In this position of tube 57 water from the condenser flows into sump 64 and drains directly to the drain via pipe 65, and the melting function is terminated. All other functions in this embodiment are as described above in relation to FIG. 1.
An electrically operated water valve modification is illustrated in FIG. 5. When container 23 is less than full, control link 27 moves upwardly, as described above, causing rocker arm 29 to rotate counter-clockwise. In addition to activating override switch 32, the rocker arm actuates a switch 66 which energizes diverter valve 67. Water from the condenser then flows from pipe 56 through diverter valve 67 to pipe 62 to warm the bottom of ice bin 18 (in the manner described in relation to FIG. 4) and then to the drain. When container 23 is full, rocker arm 29 reverses rotation, opens override switch 32, opens switch 66 and de-energizes diverter valve 67. Then, any warm water received from the condenser drains via pipe 65 directly to the drain, and the melting function is terminated.
The embodiment illustrated in FIG. 6 provides an alternative method of ice melting. With container 23 full, a downward force is exerted on control link 27, causing a clockwise rotation of rocker arm 29 to hold switch 68 open. Current flow to solenoid valves 69 and 70 is interrupted so that these valves remain de-energized. With bin switch 21 closed, indicating that the bin is less than full, compressor 9 continues to run. Solenoid valve 70 is a normally open valve; thus, since it is de-energized, valve 70 permits refrigerant fluid discharged by compressor 9 to flow to condenser 71. Solenoid valve 69 is a normally closed valve; thus, since it is de-energized, it is closed. Condenser 71 may be either air-cooled or water-cooled. Refrigerant liquid flows through check valve 72 to liquid line 11, then to metering device 12 and evaporator 2 in the ice making function previously described in relation to FIG. 1. If some of the water is removed from container 23, control link 27 is caused to move upwardly. Rocker arm 29 then rotates counter-clockwise, override switch 32 is closed, and switch 68 is permitted to close, thereby completing a circuit to energize both solenoid valves 69 and 70. When the normally open solenoid valve 70 is energized, it closes to shut off refrigerant flow to condenser 71. When normally closed solenoid valve 69 is energized, it opens to allow flow of hot refrigerant gas through pipe 73 to coil 74 mounted under ice bin 18. Coil 74 acts as a condenser rejecting heat of condensation to melt ice pieces in ice bin 18. Condensed liquid refrigerant from coil 74 flows throughpipe 75 and check valve 76 to liquid line 11. Check valve 72 serves to block backflow into condenser 71. Liquid flow in liquid line 11 continues as part of the ice making function previously described.
Coil 74 is placed so that it is not in metal-to-metal contact with the bottom of ice bin 18; therefore a condensing temperature greater than the ice melting temperature of 32° F. can be maintained. An air gap is provided so that thermal energy transfer can be accomplished by radiation and, to some extent, by convection; alternatively a layer of semi-conducting material, such as plastic, may be used to separate the coil from the ice bin bottom. In this way, the condensing temperature in coil 74 can be maintained at about 110° F., while the melting temperature is around 32° F.; the resulting 78° F. temperature gradient extends through the separating gap. Thermostat 77, with its sensing bulb 78 on the bottom of ice bin 18, is of the break-on-rise type and senses the presence of ice in the bottom of the bin. With no ice pieces present, the temperature at the bulb rises and breaks a circuit to solenoid valves 69 and 70. This prevents the system from using coil 74 as a condenser when there is no ice in the bin, as this would be an unworkable function.
The typical procedure for water handling is to use a one gallon plastic water bottle 23 (FIG. 7) which is positioned inside the housing on platform 24 and is usually full. FIG. 7 illustrates how bottle 23 may be kept within the insulated walls 79 of the machine housing or cabinet, thereby assuring that the purified liquid is kept cool for use. When the purified water is to be used, the bottle is taken from the machine and replaced by an empty bottle; alternatively, the original bottle is replaced partially full.
An alternative water storage arrangement, illustrated in FIG. 8, employs a water tank 80 mounted permanently within the housing or cabinet of the machine. Pipe 22 delivers purified liquid water to the tank 80, and spigot 81 is used to dispense that water as needed. A float 82 on arm 83 rotates about fixed pivot point 84 so as to rise and fall with the water level in tank 80. Extension 85 of arm 83 is connected to control link 27 to activate rocker arm 29 in the manner described above in relation to FIGS. 1, 3, 4, 5 and 6. Tank 80, with float 82, is thus a substitute for bottle 23, platform 24 and balancing spring 26 (FIGS. 1, 3, 4, 5 and 6). A drop in water level in tank 80 causes float 82 to drop, forcing control link 27 to move upwardly in the same manner that the reduction of water in bottle 23 (FIG. 1) causes balance spring 26 to pull platform 24 and control link 27 upwardly.
The ice pieces, of course, may be removed from the bin for use in drinks, or other purposes at any time, via bin door 86.
From the foregoing description it will be appreciated that the invention makes available a novel ice maker and water purifier wherein both small purified ice pieces and purified water are produced and stored for use in a common cabinet or housing.
Having described preferred embodiments of a new and improved ice maker and water purifier in accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims. | Purified ice pieces of a size suitable for use in drinks, and purified liquid water, are derived from unpurified liquid water by directing a stream of the unpurified water over areas of at least one freezing surface. As ice forms at the freezing surface, impurities in the water are washed away by the stream which may be collected so that the unpurified water may be recirculated as part of the freezing process. The freezing surface areas are periodically heated to detach the ice, the detached ice being collected in a bin. Ice at the bottom of the bin is melted by selectively heating the bin to provide purified water that is collected in a container. Controls are provided to automatically initiate bin heating and thereby maintain a predetermined amount of purified liquid water in the container. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to brushing, scrubbing and general cleaning, and specifically to a hand-held machine for power scrubbing.
To replace tedious manual scrubbing which is common in household cleaning, several forms of power scrubbers have been developed. These power scrubbers have had electric motors within sturdy housings to rotate a scrubbing brush mounted on the shaft of the motor. In some cases the motors have been battery-powered, enabling the scrubber to be used anywhere without a bothersome cord. The rotary brushes usually have had a generally circular shape.
Although these previous scrubbers have been small, lightweight and easily handled, they have had many disadvantages. The rotary scrubbing motion is not as effective as the traditional manual scrubbing motion. A person manually scrubbing a surface uses a back-and-forth movement which is not effectively simulated by the rotary motion of prior art scrubbers. Also, the circular brush of these previous scrubbers cannot fit into corners or other tight spots. Thus, the user was forced to rely on manual scrubbing to finish the job.
SUMMARY OF THE INVENTION
The scrubber of the present invention overcomes the disadvantages of the prior art by providing a hand-held electrically powered scrubber which simulates the back-and-forth movement of manual scrubbing and which has a triangular brush which fits into corners.
It is an object of the present invention to provide an improved electrically powered hand-held scrubber.
Another object is to provide a scrubber which produces a reversing back-and-forth movement which breaks through the dirt surface quicker than a constant rotary motion.
Still another object is to provide an electric power scrubber which has a generally triangular-shaped brush capable of fitting easily into corners and other tight spots into which a conventional circular brush cannot fit.
Yet another object is to provide a power scrubber which can thoroughly clean irregular shapes and texturized surfaces.
Another object is to provide a power scrubber which produces a concentrated cleaning motion, enabling the scrubber to be used in cramped areas such as the bottom of garbage cans and wastebaskets.
Another object is to provide a lightweight all-purpose hand-held power scrubber which can be used dry to dust or used wet with cleansers to scrub.
Another object is to provide an electrically powered scrubber which has a hand grip and an oscillatory back-and-forth motion which simulates as closely as possible the user's established habits of cleaning.
Another object is to provide an electrically powered scrubber which can receive an interchangeable variety of attachments best suited to different cleaning tasks.
These and other objects are accomplished by the scrubber according to the present invention in which a generally triangular-shaped brush is attached to a sealed housing which has a configuration to be easily gripped by hand. Within the housing is an electric motor which drives an eccentric. Around the eccentric is a yoke formed around a hole in a plate. The plate turns an attached oscillatory shaft in a reciprocating rotary back-and-forth motion. The generally triangular-shaped brush is removably mounted on the oscillatory shaft. Alternatively, the yoke can be formed around a hole in the body of the brush so that the wheel oscillates the brush when the brush is mounted on the shaft.
Preferably, the motor is powered by a rechargeable battery contained in the housing, enabling the scrubber to be used anywhere without the restriction of an electric cord. Also, a switch is preferably provided on the handle of the housing to enable the user to turn the scrubber on and off easily. The preferred embodiment of the present scrubber can be provided with a variety of different brushes. Depending upon the type of cleaning or dusting to be accomplished, the proper brush can be removably mounted on the oscillating shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the scrubber of the present invention;
FIG. 2 is a bottom view taken along the line 2--2 of FIG. 1 showing a preferred scrubbing brush;
FIG. 3 is a sectional view of the scrubber interior taken along the line 3--3 of FIG. 2;
FIG. 4 is a bottom view of the oscillating mechanism of the scrubber taken along the line 4--4 of FIG. 3;
FIG. 5 is another view of the mechanism of FIG. 4 showing the oscillation motion in broken and solid lines;
FIG. 6 is a sectional view similar to FIG. 3 showing an alternative embodiment of the scrubber of the present invention; and
FIG. 7 is a plan view of the brush mount taken along the line 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to the drawings and initially to FIG. 1, there is shown an electric power scrubber according to the present invention having a sealed housing 10. The housing 10 is sealed to be as waterproof as possible to protect the power means inside against damage from water associated with scrubbing tasks. Preferably, the housing 10 is made from a sturdy molded plastic material such as ABS polymers, acetal copolymers and homopolymers, high density polyethylenes and the like. The housing 10 has a generally flat bottom 11 and an upper portion designed to be easily gripped by hand. The upper portion of the housing 10 includes a handle portion 12 and a recessed portion 13, which together provide a comfortable hand-grip shape. The hand-grip configuration allows the user of the scrubber to grip the scrubber in the same way that the user would grip a sponge, rag or ordinary scrub brush. Protruding from the forward end of the handle portion 12 is a switch button 14. By pushing in the switch button 14, the user can start and stop the power means within the housing.
As shown in FIG. 3, the button 14 is operatively connected to a switch 16 mounted on a bracket 17 which is secured to a mounting plate 18. The switch 16 is connected to the power means of the scrubber which includes a motor 19 mounted on the bracket 17. The motor 19 is a conventional electric small-appliance or power-tool motor having adequate power to drive the scrub brush when pressed against a dirty surface. A variable-speed motor may be used, in which case the switch 16 may be a speed control switch. The motor 19 is connected to a supply of electric power. Preferably, the electric power supply comprises nickel cadmium storage cells 22 mounted within the housing 10. While electric power could also be supplied from an ordinary electric outlet via a plugged-in cord, the storage cells 22 allow the scrubber to be used anywhere without the restrictions of a cord. A nickel cadmium battery, or other rechargeable battery, is preferred so that the scrubber can be easily recharged from ordinary house current when not in use and the expense of replaceable batteries is avoided. The rechargeable battery 22 is connected to a socket 26 into which a plug can be inserted when the scrubber is not in use, enabling the battery 22 to be recharged. The rechargeable batteries may also be designed as a unit that could be slipped in and out of the scrubber and charged separately.
A rotating shaft 28 emerges from the motor 19 and provides the motor power to the oscillating means below. Preferably, a reduction gearing means 30 is provided to reduce the speed of the oscillating brush from that of the rotating motor and to increase the power of the oscillating brush. The slower, more powerful oscillating movement is preferred since it allows the user to apply greater pressure to the scrubbed surface without stalling the motor and without excessive reaction forces produced by higher oscillating speeds. The gearing means 30 comprises a gear 32 mounted on the shaft 28 and a larger gear 34 mounted on a shaft 35 driven thereby. Preferably, the gears 32 and 34 are made from nylon such as nylon 66 or an equivalent material.
Mounted on the shaft 35 coaxially with the larger gear 34 is a cam or eccentric 36. The eccentric 36 fits within a yoke 38 formed around a hole in a plate 40. The yoke 38 is preferably made from acetal homopolymer (Delrin) or an equivalent material. The plate 40 is parallel to and just above the housing bottom 11. Attached to the plate 40 is a shaft 42 which is pivotally mounted through a flange 43 attached to the mounting plate 18. The shaft 42 provides a pivot for the movement of the plate 40.
The movement of the oscillating means can be seen by comparing the solid and broken lines of FIG. 5. As the smaller gear 32 rotates the larger gear 34, it turns the eccentric 36. The yoke 38 around the eccentric 36 oscillates, swinging the plate 40 in an arcuate to-and-fro oscillatory motion. At the shaft 42, the motion becomes a purely oscillating rotary motion in which the shaft 42 rotates back-and-forth in a reciprocatory or oscillatory manner. By this means the rotary motion of the motor shaft 28 is converted into the oscillating motion of the shaft 42.
The shaft 42 extends through an opening in the bottom 11 of the housing. Mounted on the shaft 42 is any one of a number of different preferred scrubbing brushes, such as a brush 50 shown in FIG. 2. The brush 50 has a generally triangular-shaped body 52 which has a hole 54 for mounting the brush on the oscillatory shaft 42. Attached to the body 52 is an inner set of bristles 56 having a generally triangular shape. Surrounding the inner bristles is a periphery of outer bristles which includes two sets of bristles 58 on each side of the brush and a forward set of bristles 60 on the nose of the brush. Each set of outer bristles 58 and 60 are mounted to the brush body 52 to extend outwardly at an angle. The outer bristles 58 and 60 enable the user to clean corners and crevices easily while the inner bristles 56 provide ability to scrub flat surfaces. Thus, the brush 50 is able to clean irregular shapes and texturized surfaces.
Alternative brushes includes those in which the inner bristles 56 are replaced by a scrub pad material (nylon with abrasive filler), such as Scotchbrite, or a sponge material or a dusting or polishing material. In addition, the inner or outer bristles may be made to any desired length or stiffness.
An alternative embodiment of the scrubber of the present invention is shown in FIGS. 6 and 7. In this embodiment the yoke 38 and the plate 40 of the previous embodiment are combined with the body 52 of the brush. The housing 10 of the scrubber has the same general configuration with an internal battery and a motor 19. A reduction gearing means 30 comprising a gear 32 on the motor shaft 28 and a larger gear 34 on the shaft 35 is provided as before.
A cam or eccentric 66 is mounted coaxially with larger gear 34 on the shaft 35. Unlike the previous embodiment, the eccentric 66 extends below the bottom 11 of the housing of the scrubber. Also extending below the housing bottom 11 is a shaft 72. The shaft 72 is pivotally mounted through the flange 43 attached to the mounting plate 18. A brush 80 is mounted on the shaft 72. The body 82 of the brush has an opening around which is formed a yoke 83 to fit over the eccentric 66. The body 82 of the brush also has a hole 84 for mounting the brush on the shaft 72. As the eccentric 66 turns, it oscillates the brush back-and-forth in an arcuate manner about the pivot formed by the shaft 72. This scrubber produces the same general movement as the scrubber of the previous embodiment, but the yoke 38 and the plate 40 have been combined with the body 52 of the brush in a single element.
The principal advantage of this form of the invention is that the configuration of the yoke opening 83 can be modified from brush to brush and thus provide varying amplitudes and speeds of oscillation by merely changing brushes. A longer yoke opening provides a larger, slower oscillation and a shorter one a smaller, faster oscillation. No other changes or adjustments are required to achieve this effect.
The scrubber of the present invention can also be provided with a storage stand having a built-in recharger which can be conveniently mounted in a kitchen near the sink. When the scrubber is mounted in the stand, the socket 26 is mounted in a plug in the storage stand which is directly connected to a recharger current. Through this means the batteries 22 are recharged whenever the scrubber is stored in the stand, enabling it to always be ready for use.
While the invention has been shown and described with respect to specific embodiments thereof, these are intended for the purpose of illustration rather than limitation. Other modifications and variations in the specific scrubber herein shown and described will be apparent to those skilled in the art, all within the intended scope and spirit of the invention. Accordingly, the invention is not to be limited to the specific embodiment herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by this invention. | An electrically powered hand-held scrubber is disclosed which comprises a scrubbing brush removably attached to a sealed housing having a configuration adapted for a hand grip. Within the housing is a motor, preferably powered by rechargeable nickel cadmium storage cells which drives an eccentric. The eccentric produces an oscillating rotary motion which is communicated to the brush. The brush is moved in an oscillating back-and-forth rotary motion rather than a constant rotary motion, resulting in a more effective cleansing action. The brush has a generally triangular shape enabling it to fit into corners and other tight spots into which a circular brush cannot fit. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to fuel burners and methods for combusting solid fuels with oxidants, including but not limited to oxygen and oxygen-enriched air, and in particular to such burners and methods for combusting pulverized solid fuels for generating heat in industrial melting furnaces for glass, ceramic materials, metals, etc.
However, the invention is not limited to use with such industrial melting furnaces. Persons skilled in the art will recognize that the burners and methods of the present invention may be used in many other fired process heating applications, including but not limited to cement kilns and steam generators.
Solid fuel burners and methods for combusting solid fuels with oxidants, such as oxygen and/or oxygen-enriched air, are well known. Various types of such burners have been developed for different industries (e.g., glass melting), including oxy-fuel burners having concentric or coaxial passages for supply of fuel and oxygen. Such burners are disclosed in U.S. Pat. No. 5,104,310 (Saltin); U.S. Pat. No. 5,743,723 (Iatrides, et al.); and U.S. Pat. No. 6,685,461 (Rio, et al.). Other such burners are taught in U.S. Pat. No. 3,894,834 (Estes); U.S. Pat. No. 4,797,087 (Gitman); U.S. Pat. No. 4,902,223 (Young); U.S. Pat. No. 4,928,605 (Suwa, et al.); U.S. Pat. No. 6,843,185 (Taylor); and U.S. Patent Application Publication No. 2003/0075843 (Wunsche).
For example, U.S. Pat. No. 3,894,834 (Estes) discloses an axially positioned oxy-fuel burner within a coal/air burner for adjusting flame length and maintaining stability.
U.S. Pat. No. 5,743,723 (Iatrides, et al.) discloses a three-tube oxy-fuel burner comprising: an oxidant source of at least 80% oxygen; an outer and an inner oxidant passage, each connected to the oxidant source; a fuel conducting passage disposed between the two oxidant passages; and a valve to regulate the flow between the oxidant passages.
U.S. Pat. No. 6,685,461 (Rio, et al.) discloses a burner similar to that of Iatrides, et al. in the '723 patent, but with several structural and operational differences. For example, the burner is fastened to a burner quarl, and a control valve is housed in the burner for adjusting oxidant flows between the two oxidizer tubes. No limits are specified for the oxygen concentration of the oxidant.
U.S. Pat. No. 5,104,310 (Saltin) discloses an oxy-fuel burner with several configurations, each requiring a central oxygen nozzle connected to an oxygen-receiving chamber (which is part of the burner), at least one fuel nozzle radially spaced from the central oxygen nozzle, and at least one peripheral oxygen nozzle at a greater radial distance from the central oxygen nozzle (relative to the fuel nozzle(s)). Several variations include one or more of the following features: part of the means for supplying fuel and oxygen to the burner is a cooling jacket for the burner; peripheral oxygen nozzle(s) of a converging-diverging design; and a fuel nozzle that transmits only fuel (i.e., no carrier gas).
In addition to the oxy-fuel burners discussed above, many other solid fuel burners have been developed for burning pulverized coal and other fuels. Such burners are disclosed in U.S. Pat. No. 4,497,263 (Vatsky, et al.); U.S. Pat. No. 5,090,339 (Okiura, et al.); U.S. Pat. No. 6,715,432 (Tsumura, et al.); U.S. Pat. No. 6,752,620 (Heier, et al.); U.S. Pat. No. 6,889,619 (Okazaki, et al.); and JP 60-194208 (Takayuki Abe).
In addition, various devices have been developed for use with pulverized coal-fired burners and furnaces, especially during low load operations. For example, U.S. Pat. No. 4,274,343 (Kokkinos) discloses a device for stabilizing ignition of coal-fired flames during low load operation. U.S. Pat. No. 4,448,135 (Dougan, et al.) and U.S. Pat. No. 6,475,267 (Lehn) disclose different types of such devices for use with burners.
The burners and devices discussed above have addressed various problems relating to fuel burners and methods for combusting solid fuels. However, many problems remain, or have not been satisfactorily addressed.
For example, the prior art has not taught a burner and method for combusting a solid fuel which satisfactorily and simultaneously attain robust flame stability, enhanced turndown, adjustability of flame properties, and the ability to combust solid fuels of greatly varying properties, in particular, both high and low volatile solid fuels (including petroleum coke).
Other problems that occur with conventional solid fuel burners, especially at turndown (i.e., reduced firing rate) conditions, include weakening of the axial momentum of the burner flame, the loss of coherent flame structure, and shortening of the flame. In general, the prior art burners do not maintain a constant (or nearly constant) flame length over an entire operating regime.
There are fuels and/or combustion applications for which oxygen/fuel (so-called oxy/fuel) combustion or oxygen-enriched air/fuel combustion provide superior results relative to air/fuel combustion. While there are prior art patents pertaining to oxygen-based, solid fuel combustion [(e.g., U.S. Pat. No. 4,928,605 (Suwa, et al.) and U.S. Pat. No. 4,902,223 (Young)], these patents do not satisfactorily and comprehensively address the aforementioned problems while also attending to the challenges distinctive to oxygen-based combustion. Such challenges relate primarily, but not exclusively, to the high temperature created by oxygen-enhanced flames and the potentially detrimental effect that these flames can have on burner and furnace components. Buffering of the burner components from the high temperature oxygen-enhanced flame is often accomplished by the use of water-cooled jackets. Although such jackets nominally protect the burner components from many instances of high temperature damage, the jackets add complexity and cost to the operation, while not mitigating against one of the principal causes of high temperature damage, which is control of flow distribution (i.e., flow profiles within the burner nozzle) and mixing patterns of the reactants. In the case of solid fuel combustion, inadequate control of reactant flow distribution and mixing leads not only to high temperature damage, but also to impingment of solid particles and subsequent erosion of burner and furnace components.
In view of these and many other problems pertaining to prior art burners and methods for combustion of solid fuels with oxidants, it is desired to have a burner and a method for combustion which overcome the difficulties, problems, limitations, disadvantages, and deficiencies of the prior art to provide better and more advantageous results.
It is further desired to have a more efficient burner and method of combustion for combusting a solid fuel with an oxidant.
It is still further desired to have a burner and a method for combusting a solid fuel which attain robust flame stability, enhanced turndown, adjustability of flame properties, and the ability to combust solid fuels of greatly varying properties, in particular both high and low volatile solid fuels.
It is still further desired to have a burner and a method for combusting a solid fuel which achieve a longer, slower mixing flame with lower peak temperature than would otherwise be achieved with prior art burners and methods.
It is still further desired to have a burner and a method for combusting a solid fuel which efficiently operate over a wider range of firing rates than is normally attainable with burners and methods of the prior art.
It is still further desired to have a burner and a method for combusting a solid fuel which strengthen the axial momentum of the burner flame and prevent the loss of coherent flame structure that occurs with conventional solid fuel burners and combustion methods.
It is still further desired to have a burner and method for combusting a solid fuel which facilitate lengthening of the burner flame at reduced loads, and thereby provide a means for maintaining nearly constant flame length over an entire operating regime.
It is still further desired to have a burner and a method for combusting a solid fuel capable of stably burning low volatile solid fuels, such as petroleum coke.
It is still further desired to have a burner and a method for combusting a solid fuel wherein flame properties can be adjusted via control of reactant mixing properties.
It is also desired to have a burner and method for combusting a solid fuel capable of supporting oxygen-enhanced or oxygen-fuel combustion.
BRIEF SUMMARY OF THE INVENTION
The present invention includes a burner and a method for combusting a solid fuel. There are multiple embodiments of the burner and the method, as well as multiple variations of those embodiments.
There are multiple elements in a first embodiment of the burner for combusting a solid fuel. The first element is a first oxidant conduit having a first longitudinal axis, a first oxidant inlet, and a first oxidant outlet spaced apart from the first oxidant inlet. The first oxidant conduit is adapted to transmit at a first flow rate a first stream of an oxidant entering the first oxidant inlet and exiting the first oxidant outlet, the oxidant having an oxygen concentration greater than about 21 vol. %.
The second element is a solid fuel conduit having a second longitudinal axis substantially parallel to the first longitudinal axis, an intake, and an outtake spaced apart from the intake. The solid fuel conduit surrounds the first oxidant conduit and thereby forms a first annulus between the first oxidant conduit and the solid fuel conduit. The first annulus is adapted to transmit a mixture of a transport gas and a plurality of particles of the solid fuel entering the intake and exiting the outtake.
A third element is a second oxidant conduit having a third longitudinal axis substantially parallel to the second longitudinal axis, a second oxidant inlet, and a second oxidant outlet spaced apart from the second oxidant inlet. The second oxidant conduit surrounds the solid fuel conduit and thereby forms a second annulus between the solid fuel conduit and the second oxidant conduit. The second annulus is adapted to transmit at a second flow rate a second stream of the oxidant or an other oxidant having an oxygen concentration greater than about 21 vol. %, said second stream entering the second oxidant inlet and exiting the second oxidant outlet.
The fourth element is means for segregating the mixture proximate the outtake into a lean fraction stream of the mixture adjacent the first oxidant conduit and a dense fraction stream of the mixture adjacent the solid fuel conduit. The dense fraction stream contains a first mass ratio of the transport gas to the solid fuel, and the lean fraction stream contains a second mass ratio of the transport gas to the solid fuel, the second mass ratio being greater than the first mass ratio.
At least a portion of the first stream of the oxidant exiting the first oxidant outlet combines during combustion with at least a portion of the lean fraction stream, thereby forming an inner combustion zone adjacent the outtake. At least a portion of the second stream of the oxidant or the other oxidant exiting the second oxidant outlet combines during combustion with at least a portion of the dense fraction stream, thereby forming an outer combustion zone near the inner combustion zone.
There are many variations of the first embodiment of the burner. In one variation, at least one of the first flow rate and the second flow rate is variable. In another variation, the second oxidant conduit and the solid fuel conduit are substantially co-axial. In yet another variation, at least two of the first oxidant conduit, the solid fuel conduit, and the second oxidant conduit are co-axial.
In another variation, the means for segregating the mixture includes a swirl generator disposed in the first annulus proximate the outtake and a vortex finder disposed in the first annulus at a distance from the swirl generator at a location between the swirl generator and the outtake, the vortex finder having a hydraulic radius less than a first hydraulic radius of the first annulus.
There are several variants of this variation. In one variant, segregation of the mixture is adjusted by either increasing or decreasing at least one of the hydraulic radius of the vortex finder and the distance from the swirl generator to the vortex finder. In another variant, the vortex finder has either swirl vanes or straightening vanes adapted to contact at least one of the lean fraction stream and the dense fraction stream. In yet another variant, the outtake of the solid fuel conduit and a portion of the vortex finder proximate the outtake form a nozzle tip profile, and the nozzle tip profile is modified by at least one of an outward divergence of the outtake and an inward convergence of the portion of the vortex finder proximate the outtake.
In another variation, both the outtake and the first oxidant outlet are substantially parallel to each other and substantially in a first plane substantially perpendicular to both the second longitudinal axis at the outtake and the first longitudinal axis at the first oxidant outlet, and a portion of the first stream of the oxidant initially contacts a portion of the lean fraction stream of the mixture at about the first plane. In a variant of this variation, a portion of the second stream of the oxidant or the other oxidant initially contacts a portion of the dense fraction stream of the mixture at about another plane spaced apart from the first plane.
A second embodiment of the burner is similar to the first embodiment of the burner, but also includes a swirler disposed in the first oxidant conduit.
A third embodiment of the burner is similar to the first embodiment of the burner, but also includes an auxiliary gas conduit having a fourth longitudinal axis substantially parallel the third longitudinal axis, an auxiliary gas inlet, and an auxiliary gas outlet spaced apart from the auxiliary gas inlet. The auxiliary gas conduit surrounds the second oxidant conduit and thereby forms a third annulus between the second oxidant conduit and the auxiliary gas conduit. The third annulus is adapted to transmit at a third flow rate a stream of an auxiliary gas entering the auxiliary gas inlet and exiting the auxiliary gas outlet.
There are multiple steps in a first embodiment of the method for combusting a solid fuel. The first step is to provide a first oxidant conduit having a first longitudinal axis, a first oxidant inlet, and a first oxidant outlet spaced apart from the first oxidant inlet. The second step is to transmit through the first oxidant conduit at a first flow rate a first stream of an oxidant having an oxygen concentration greater than about 21 vol. %, the first oxidant entering the first oxidant inlet and exiting the first oxidant outlet. The third step is to provide a solid fuel conduit having a second longitudinal axis substantially parallel the first longitudinal axis, an intake and an outtake spaced apart from the intake, the solid fuel conduit surrounding the first oxidant conduit and thereby forming a first annulus between the first oxidant conduit and the solid fuel conduit. A fourth step is to transmit through the first annulus a mixture of a transport gas and a plurality of particles of the solid fuel, the mixture entering the intake and exiting the outtake. The fifth step is to provide a second oxidant conduit having a third longitudinal axis substantially parallel the second longitudinal axis, a second oxidant inlet, and a second oxidant outlet spaced apart from the second oxidant inlet, the second oxidant conduit surrounding the solid fuel conduit and thereby forming a second annulus between the solid fuel conduit and the second oxidant conduit. The sixth step is to transmit through the second annulus at a second flow rate a second stream of the oxidant or an other oxidant having an oxygen concentration greater than about 21 vol. %, the second stream entering the second oxidant inlet and exiting the second oxidant outlet. The seventh step is to segregate the mixture proximate the outtake into a lean fraction stream of the mixture adjacent the first oxidant conduit and a dense fraction stream of the mixture adjacent the solid fuel conduit, the dense fraction stream containing a first mass ratio of the transport gas to the solid fuel, and a lean fraction stream containing a second mass ratio of the transport gas to the solid fuel, the second mass ratio being greater than the first mass ratio. The eighth step is to combust at least a portion of the first stream of the oxidant with at least a portion of the lean fraction stream, thereby forming an inner combustion zone adjacent the outtake. The ninth step is to combust at least a portion of the second stream of the oxidant or the other oxidant with at least a portion of the dense fraction stream, thereby forming an outer combustion zone near the inner combustion zone.
There are many variations of the first embodiment of the method for combusting a solid fuel. In one variation, at least one of the first flow rate and the second flow rate is variable. In another variation, the first oxidant conduit and the solid fuel conduit are substantially co-axial. In yet another variation, at least two of the first oxidant conduit, the solid fuel conduit, and the second oxidant conduit are co-axial. In still yet another variation, a swirler is disposed in the first oxidant conduit.
In another variation, a swirl generator is disposed in the first annulus proximate the outtake, and a vortex finder is disposed in the first annulus at a distance from the swirl generator at a location between the swirl generator and the outtake, the vortex finder having a hydraulic radius less than a first hydraulic radius of the first annulus. In a variant of this variation, segregation of the mixture is adjusted by either increasing or decreasing at least one of the hydraulic radius of the vortex finder and the distance from the swirl generator to the vortex finder. In another variant, the vortex finder has either swirl vanes or straightening vanes adapted to contact at least one of the lean fraction stream and the dense fraction stream. In yet another variant, the outtake of the solid fuel conduit and a portion of the vortex finder proximate the outtake form a nozzle tip profile, and the nozzle tip profile is modified by at least one of an outward divergence of the outtake and an inward convergence of the portion of the vortex finder proximate the outtake.
In another variation of the method for combusting a solid fuel, both the outtake and the first oxidant outlet are substantially parallel to each other and substantially in a first plane substantially perpendicular to both the second longitudinal axis at the outtake and the first longitudinal axis at the first oxidant outlet, and a portion of the first stream of the oxidant initially contacts a portion of the lean fraction stream of the mixture at about the first plane. In a variant of this variation, a portion of the second stream of the oxidant or the other oxidant initially contacts a portion of the dense fraction stream of the mixture at about another plane spaced apart from the first plane.
A second embodiment of the method for combusting a solid fuel is similar to the first embodiment but includes two additional steps. The first additional step is to provide an auxiliary gas conduit having a fourth longitudinal axis substantially parallel to the third longitudinal axis, an auxiliary gas inlet, and an auxiliary gas outlet spaced apart from the auxiliary gas inlet, the auxiliary gas conduit surrounding the second oxidant conduit and thereby forming a third annulus between the second oxidant conduit and the auxiliary gas conduit. The second additional step is to transmit through the third annulus at a third flow rate a stream of an auxiliary gas entering the auxiliary gas inlet and exiting the auxiliary gas outlet.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
The invention will be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a side view of one embodiment of the invention;
FIG. 2 is a schematic diagram of a front view of one embodiment of the invention;
FIG. 3 is a schematic diagram of a side view illustrating the use of a solid fuel swirl generator and a vortex finder for one embodiment of the invention;
FIGS. 4A and 4B are schematic diagrams of a side view of several embodiments of the invention using different vortex finders, each having a relative difference in radius;
FIG. 5A is a schematic diagram of a side view of one embodiment of the invention using a vortex finder with swirl vanes;
FIG. 5B is a schematic diagram of a side view of one embodiment of the invention using a vortex finder with straightening vanes;
FIG. 6A is a schematic diagram of a side view of one embodiment of the invention using a vortex finder having an inward converging tip;
FIG. 6B is a schematic diagram of a side view of another embodiment of the invention using a solid fuel nozzle having an outward diverging tip;
FIG. 7 is a schematic diagram illustrating a solid fuel/outer oxidant interface and two combustion zones, an inner combustion zone and an outer combustion zone, for one embodiment of the invention;
FIG. 8 is a schematic diagram illustrating a flame for a conventional pulverized coal burner;
FIG. 9 is a schematic diagram illustrating a swirled flame for a conventional pulverized coal burner;
FIG. 10 is a schematic diagram illustrating a pulverized solid fuel entrained into a high momentum central oxidant jet; and
FIG. 11 is a schematic diagram illustrating an embodiment of the invention using a swirler in an inner oxidant conduit.
DETAILED DESCRIPTION OF THE INVENTION
The invention includes burners and a methods for combusting a solid fuel with an oxidant. As used herein, the term “solid fuel” refers to any solid fuel suitable for combustion purposes. Although the invention is discussed in the context of a pulverized coal burner, various types of coal and other solid fuels may be used with the burners and methods of the present invention.
For example, the invention may be used with many types of carbonaceous fuels, including but not limited to: anthracite, bituminous, sub-bituminous, and lignitic coals; tar; bitumen; petroleum coke; paper mill sludge solids and sewage sludge solids; wood; peat; grass; and combinations and mixtures of all of those fuels.
As used herein, the term “oxidant” refers to oxygen, oxygen-enriched air, or any other suitable oxidant with an oxygen concentration greater than about 21% by volume. One possible oxidant is commercially pure oxygen generated by a cryogenic air separation plant, a membrane or an adsorption process. The oxygen concentration of such oxidant is typically greater than 90% by volume.
As used herein the term “auxiliary gas” is a gas or mixture of gases (e.g., air, nitrogen, oxygen or recirculated products of combustion) having an oxygen concentration different than the oxygen concentration of either the primary or secondary oxidant used with a particular embodiment of the invention.
The oxygen-enriched pulverized solid fuel burner 10 shown in FIGS. 1 and 2 achieves improved turndown, flame stability, and control of flame temperature, length, and shape, particularly for low volatile solid fuels. The burner includes three passages—an inner oxidant passage 12 and an annular oxidant passage 14 surrounding an annular solid fuel/transport gas passage 16 . An optional outer annulus passage 18 may be used for an auxiliary gas. Enhanced performance may be achieved relative to conventional solid fuel burner technology through the adjustment of inner and outer oxidant flows, control of reactant flow profiles, and adjustment of reactant velocities.
Referring to FIG. 1 , a stream 20 of an oxidant enters the inlet 22 of the inner oxidant passage 12 and is transmitted to the outlet 24 of said passage. Another stream 26 of the oxidant (or another oxidant) enters the inlet 28 of the annular oxidant passage 14 and is transmitted to the outlet 30 of said passage. A stream 32 of an optional auxiliary gas may be transmitted from the inlet 34 of the optional outer annulus passage 18 to the outlet 36 of said passage. A stream 38 of a mixture of a transport gas (e.g., air, nitrogen, recirculated products of combustion, natural gas, oxygen-enriched air) and a solid fuel (e.g., pulverized coal) enters the intake 40 of the annular solid fuel/transport gas passage 16 and is transmitted to the outtake 42 of said passage.
As shown in FIGS. 1 and 3 , a solid fuel stratifier 44 and a separator 46 are disposed in the annular solid fuel/transport gas passage 16 . The combination of the solid fuel stratifier and the separator divides the mixture of the fuel and the transport gas into two streams with distinct properties.
Persons skilled in the art will recognize that there are various devices and methods for carrying out the stratification and separation processes (the combination of which is referred to hereafter as segregation). One embodiment discussed herein uses a swirl generator as the solid fuel stratifier 44 and a vortex finder as the separator 46 . The swirl generator employs centrifugal forces to stratify the solid fuel/transport gas stream into an outer dense fraction stream 48 and an inner lean fraction stream 50 , as shown in FIGS. 2 and 3 . The mass ratio of the solid fuel to transport gas in the lean fraction stream is less than the mass ratio of solid fuel to transport gas in the dense fraction stream. Centrifugal forces also effect the stratification based on particle size, such that the dense fraction stream generally comprises a greater percentage of coarse particles than the lean fraction stream.
One advantage of achieving this type of segregation is that the outer dense fraction stream 48 heats up more rapidly because it is deficient in transport gas which would otherwise absorb much of the locally available thermal energy. Hence, volatile species present in the solid fuel are driven off at a higher rate and combust more rapidly than if the stream was more dilute. Thus, the burner flame auto-ignites at a position closer to the burner tip and is inherently more stable than if the burner 10 did not have this segregating capability. That is, the burner flame front will form closer to the burner exit plane and be less likely to exhibit instabilities or extinguish due to process perturbations. Further, since the combustion of volatiles occurs closer to the burner tip, the local gaseous environment is more fuel-rich than if the volatiles combustion had been delayed. This facilitates a reduction in NOx emissions relative to a non-segregated stream.
The lean fraction stream 50 , which consists of generally finer solid particles with higher surface area to volume ratio than exists in the dense fraction stream 48 , exits the burner 10 adjacent the inner oxidant stream 20 . Combustion of the lean fraction stream is accelerated by fine solid particles having a high surface area per unit volume and the enhanced oxidizing ability of the oxygen-enriched inner oxidant stream. Combustion products of the lean fraction stream thus contribute thermal energy and chemically active species (radicals) that further assist in igniting and stabilizing the dense fraction stream.
Segregation properties of solid particles in the outer dense fraction stream 48 and the inner lean fraction stream 50 can be altered by changing the size and/or radial positioning of the vortex finder (separator 46 ), as shown in FIGS. 4A and 4B . For purposes of illustration, FIG. 4A represents a base case wherein the vortex finder has a certain hydraulic radius, and the relative solid particle to transport gas mass flow ratio of the dense fraction stream 48 and the lean fraction stream 50 are indicated by the relative differences in shading of those streams in the base case (darker shade represents higher mass flow ratio of solid particles to transport gas). In the embodiment shown in FIG. 4B , the vortex finder has a larger hydraulic radius relative to the base case. The higher solid particle to transport gas mass flow ratio of the dense fraction stream 48 in this figure is indicated by darker shading (relative to the dense fraction stream 48 in the base case), while the lean fraction stream 50 of FIG. 4B also has a darker shading than the lean fraction stream of the base case.
The term “hydraulic radius” as used herein is equal to twice the ratio of the cross-sectional area inside the boundaries of the vortex finder to the perimeter of the vortex finder. Persons skilled in the art will recognize that the separation device (in this case, vortex finder) can take on a variety of cross-sectional shapes including, but not limited to, circular, elliptical, polygonal, or other irregular shapes or combinations thereof. Moreover, adjustment of the solid particle to transport gas mass flow ratio can also be made through variation of the axial separation distance, d, between the stratification and separation devices (see FIG. 5A ).
As shown in FIGS. 5A and 5B , the aerodynamic properties of the stream 38 (see FIG. 1 ) of the mixture of solid fuel and transport gas may be modified by using devices such as swirl vanes 52 or straightening vanes 54 in the vortex finder (separator 46 ). FIG. 5A illustrates a vortex finder with swirl vanes, while FIG. 5B illustrates a vortex finder with straightening vanes. Swirl vanes act to increase the mixing rate between fuel and oxidant, thereby shortening the flame, while straightening vanes streamline the solid fuel/transport gas stream, thus slowing the rate of mixing, lowering peak temperatures, and lengthening the flame. The vanes, or similar devices, can act as flow modifiers for either the lean fraction stream 50 or the dense fraction stream 48 of the solid fuel/transport gas mixture, or both, thereby tailoring the mixing of the reactants to the desired properties of the flame.
The flow and mixing characteristics of the two streams (dense fraction stream 48 and lean fraction stream 50 ) may also be altered by profile modifications to the nozzle tip of the burner 10 , as shown in FIGS. 6A and 6B . FIG. 6A illustrates inward convergence of a vortex finder tip 60 , which causes the lean fraction stream 50 to mix more rapidly with the inner oxidant at the burner nozzle outlet. FIG. 6B illustrates outward divergence of a solid fuel nozzle 62 , which produces a radial expansion of the dense fraction stream 48 exiting the burner nozzle, and subsequently leads to a low pressure core of reverse or recirculating flow downstream of the burner nozzle outlet. This type of flow is advantageous for promoting flame stability. The features of FIGS. 6A and 6B may be combined, resulting in a nozzle tip having an inward convergence of the vortex finder tip and an outward convergence of the solid fuel nozzle. Persons skilled in the art will recognize that flow and mixing characteristics may also be altered by adjusting the relative axial position of the outlet planes of the various reactant streams.
An important advantage of the present invention is the ability to create two distinct combustion zones via mixing of the inner and outer oxidant streams with the lean and dense fraction streams, respectively. FIG. 7 illustrates an embodiment of the invention in which such an advantage is achieved by directing the inner lean fraction stream 50 radially inward toward the inner oxidant stream 20 . A relatively small and stable inner flame 64 is thereby generated adjacent the burner nozzle exit. An outer flame 65 is also formed, principally comprising the dense fraction stream 48 , the outer oxidant stream 26 and recirculated products of combustion 66 . A swirl is imparted to the outer flame causing a region of reverse flow 68 to form. Recirculated material 66 from this region of reverse flow interacts directly with the inner flame 64 , causing the recirculated material to heat up and/or ignite. This heated (or ignited) recirculated material then reverses direction again as it brings its thermal energy and/or ignition source into the outer flame, further augmenting the rate of release and combustion of volatile species from the outer flame, improving flame stability and lowering NOx emissions. Moreover, the outer interface of the fuel-rich, dense fraction stream 48 benefits from interacting with the oxygen-rich, outer oxidant stream 26 . Accelerated heating at this interface further improves stability while increasing thermal radiation from the outer flame and reducing carbon carryover. Persons skilled in the art will recognize that there may be other methods of mixing the reactant streams using the present invention, and respective benefits may be derived therefrom.
An important feature of the present invention is that the solid fuel/transport gas stream 38 contacts the two oxidant streams ( 20 , 26 ) on two interfaces at two distinct radii. This increases the surface contact area between the fuel/transport gas and oxidant while also reducing the effective thickness of the fuel/transport gas stream over which the oxidant and the fuel mutually diffuse. This accelerates reaction of the fuel compared to conventional burners in which fuel and oxidant share only a single interface.
An additional advantage of this configuration lies in the ability to vary the flow rate and velocity of the oxidant streams ( 20 , 26 ) and thereby control the shear force at both the inner and outer interfaces of the fuel/transport gas stream 38 . Hence, for example, if a low volatile solid fuel is employed or a relatively short flame is desired, then the velocities of the inner and outer oxidant streams ( 20 , 26 ) at the burner nozzle exit would be designed to be different than those of the lean and dense fraction streams ( 48 , 50 ). In particular, if the velocity of the outer oxidant stream 26 is substantially greater than that of the dense fraction stream 48 , and the velocity of the inner oxidant stream 20 is substantially less than that of the lean fraction stream 50 , the shear rates will be relatively high, promoting rapid mixing and dissipation of axial momentum, leading to a relatively short and stable flame. By contrast, if a high volatile solid fuel is employed or a long, relatively low temperature flame is desired, then the velocities of the oxidant and the fuel streams at the burner nozzle outlet would be maintained at approximately the same magnitude, thus minimizing shear rates, and slowing the rate of dissipation of axial momentum and reactant mixing.
One limitation of many prior art solid fuel burners is the notoriously narrow range of fuel firing rate. This typically occurs due to breakdown of the axial momentum of the solid fuel/transport gas stream at turndown conditions. As shown in FIG. 8 , the flame 70 tends to become very lazy with a consequent breakdown of the flame structure at positions relatively close to the burner nozzle exit plane 72 . While swirl 74 , as shown in FIG. 9 , can be added to the pulverized fuel/transport gas stream to preserve a coherent flame structure, this has the added effect of shortening and broadening the flame 76 , which is not always desirable.
The present invention preserves the coherent flame structure at turndown by increasing the flame momentum via an increase of flow to the inner oxidant passage 12 . As shown in FIG. 10 , the pulverized solid fuel 78 is entrained into a high momentum central oxidant jet 80 . This action strengthens the burner flame structure, thus allowing greater penetration of the flame into the process heating zone without it succumbing to buoyancy-induced distortions, which are inherently difficult to control in a turbulent combustion environment. This aspect of the invention is particularly crucial in applications where loss of control of flame shape, length, or trajectory is detrimental to process safety or efficiency.
Persons skilled in the art will recognize that the split of oxidant flow rate between the inner oxidant passage 12 and the annular oxidant passage 14 may be varied in several ways. For example, a valve(s) may be used to vary the flows to the two passages. Another way is to use an automatic flow controller and two metered lines which are controlled independently to supply oxidant(s) to the two passages.
Depending on solid fuel properties and process constraints, it is sometimes desirable to further enhance flame stability through the use of a swirl generator (or swirler) 84 in the inner oxidant passage 12 , as illustrated in FIG. 11 . This inner oxidant swirler 84 , when utilized, generates a small recirculation zone along the burner axis that, by virtue of its magnitude and location, assists in anchoring the flame by promoting entrainment and recirculation of the pulverized solid fuel, and by increasing residence time and heat release immediately downstream of the burner nozzle outlet.
The present invention enhances burner flame stability by segregating the stream of the solid fuel/transport gas mixture just prior to its discharge from the burner nozzle, increasing the rate of particle heat up and devolatilization, and by surrounding the stream of the solid fuel/transport gas mixture on both sides by oxidant streams. Also, burner turndown range is expanded by varying, in a controlled manner, the proportion of oxidant flow to the outer and inner oxidant passages. Thus, at turndown (i.e., reduced firing rate) conditions, the proportion of inner to outer oxidant is increased, thereby strengthening the axial momentum of the burner flame and preventing the loss of coherent flame structure that occurs with conventional solid fuel burner technology. By the same mechanism, the present invention also facilitates lengthening of the flame at reduced loads. Hence, the present invention provides a means for maintaining nearly constant flame length over the operating regime.
Although illustrated and described herein with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. | A burner includes a first oxidant conduit to transmit a first stream of an oxidant; a solid fuel conduit having an outtake and surrounding the first oxidant conduit, thereby forming a first annulus to transmit a mixture of a transport gas and particles of a solid fuel; a second oxidant conduit surrounding the solid fuel conduit, thereby forming a second annulus to transmit a second stream of the oxidant or an other oxidant; and means for segregating the mixture proximate the outtake into a lean fraction stream and a dense fraction stream. The first stream of the oxidant exiting the first oxidant conduit combines during combustion with the lean fraction stream, thereby forming an inner combustion zone adjacent the outtake, and the second stream of the oxidant, or the other oxidant, exiting the second oxidant conduit combines during combustion with the dense fraction stream, thereby forming an outer combustion zone. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/508,378, filed Jul. 15, 2011, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of in-vehicle entertainment. More particularly, the invention relates to a device that mounts a tablet computer onto the support posts of a vehicle headrest.
SUMMARY
[0003] One embodiment of the present invention utilizes a two-piece mount to attach a tablet computer to a vehicle headrest. The first piece constitutes a tablet housing, having a rigid core attached to a flexible outer rim portion. The flexible rim portion is sized so that it can stretch around the circumference of the tablet computer and hold the tablet securely within the tablet housing. The tablet housing is open in the front to allow full access to the front of the tablet, and smooth and thin at the back to allow the tablet computer to be comfortably used by a user while the tablet remains within the tablet housing. In effect, the tablet housing acts as a protective case for the tablet computer.
[0004] The tablet housing has a rigid core portion with a circular cavity in the rear. In the circumference of the circular cavity is a circular groove or channel. The tablet housing can be attached to the headrest coupling portion of the mount through this circular groove. The headrest coupling contains a circular attachment disk that fits within the circular cavity. On the edge of the attachment disk is at least one retractable tab that extends away from the attachment disk. This tab can be retracted to allow the attachment disk of the headrest coupling to be inserted into the circular cavity of the tablet housing. The tab can be extended into the groove within the circumference of the circular cavity. The tab interacts with the groove to prevent the tablet housing from falling off of the attachment disk of the headrest coupling. In one embodiment, the tablet housing can rotate with respect to the headrest coupling, with the tab of the attachment disk rotating within the groove of the circular cavity. Stops within the groove of the circular cavity can limit the rotation of the tablet housing. In the preferred embodiment, the tab allows the tablet housing to rotate ninety degrees from a horizontal position to a vertical position.
[0005] The headrest coupling uses two hinged arms to lock the headrest coupling to the post of the headrest in the vehicle. A toothed gripping surface on the interior of the hinged arms and the exterior of the base of the headrest coupling help prevent the headrest post from slipping, while a locking clip tightly holds the hinged arms in place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of one embodiment of a headrest mount for a tablet computer.
[0007] FIG. 2 is an exploded, perspective view the headrest mount of FIG. 1 .
[0008] FIG. 3 is a perspective view of a tablet housing containing a tablet computer.
[0009] FIG. 4 is a perspective view of a headrest coupling being attached to the headrest poles of a vehicle headrest.
[0010] FIG. 5 is a perspective view of a left attachment mechanism of a headrest coupling.
[0011] FIG. 6 is a view of the attachment mechanism of FIG. 5 , with a closed locking clip.
[0012] FIG. 7 is an exploded view of the headrest mount of FIG. 3 , showing the rear of the tablet housing.
[0013] FIG. 8 is an exploded, top plan view of a headrest mount.
[0014] FIG. 9 is the top plan view of the headrest mount with the tablet housing attached to the headrest coupling.
[0015] FIG. 10 is a front plan view of a headrest mount showing the rotational position of a tablet housing in phantom.
[0016] FIG. 11 is a right plan view of a headrest mount showing the tilted positions of the tablet housing in phantom.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 shows one embodiment of a headrest mount 10 for a tablet computer. The mount 10 consists of two separable elements. The first element is the headrest coupling 100 , which attaches the mount 10 to the headrest support poles (not shown). The second element is the tablet housing 200 , which serves to hold and protect the tablet computer (also not shown). The headrest coupling 100 utilizes two hinged arms 110 , each of which rotates about a hinge mounted in the main body 120 of the headrest coupling 100 . Inside each hinged arm 110 is a toothed gripping surface 112 formed of a rubber or rubber-like synthetic compound. The surface 112 has individual ridges or teeth to help hold the headrest support posts when the headrest mount 10 is positioned within a vehicle. The toothed gripping surface 112 is also found on the corresponding exterior surface of the main body 120 , as shown in FIG. 1 , so as to surround the headrest post with the surface 112 on two sides. The hinged arms 110 are held closed by clip 130 located on the two ends of the elongated main body 120 .
[0018] The main body 120 of the headrest coupling 100 will preferably also have constructed into it a power plug holder 122 . In the disclosed embodiment, this holder 122 is a recess in the main body 120 . Inside this recess is a plug made out of an elastic rubber or rubber-like synthetic compound, with this plug itself containing an interior recess 124 . The interior recess 124 in the plug holder 122 is sized and shaped to receive a portion of a charging cable used to charge the tablet computer that is mounted into the headrest mount 10 . In the embodiment shown in FIG. 1 , the interior recess has an elongated, narrow cross-section, designed to receive a plug that is itself inserted into the tablet computer.
[0019] The tablet housing 200 is itself constructed of two primary components, namely a rigid core 210 and a flexible rim or exterior 220 . In the preferred embodiment, the rigid core 210 is formed out of a rigid plastic and has flanges 212 to help secure the core 210 to the rim 220 . The flexible rim 220 is formed from a rubber or rubber-like synthetic compound that allows the rim 220 to be slightly stretched and then return to its original shape. The rim 220 preferably contains a plurality of apertures or tablet control access ports 222 near the outer periphery of the rim 220 . These ports 222 are sized and located to allow access to control buttons and interfaces of the tablet computer when the tablet is inserted into the tablet housing 200 .
[0020] FIG. 2 shows the headrest mount 10 with the headrest coupling 100 separated from the tablet housing 200 . In this figure, headrest coupling 100 is attached to posts 320 that extend between a vehicle seat 300 and the seat's headrest 310 . The hinged arms 110 of the headrest coupling 100 each wrap around one of the posts 320 , trapping the posts 320 between the toothed gripping surface 112 of the arms 110 and the toothed gripping surface 112 found on the body 120 of the headrest coupling 100 . The locking clips 130 are in the closed position, preventing the hinged arms 110 from moving and compressing the arms 110 against the posts 320 .
[0021] The headrest coupling 100 attaches to the tablet housing 200 via an attachment disk 140 that extends from the main body 120 of the coupling 100 . In one embodiment, the attachment disk 140 connects to the body 120 via a hinge 150 , which allows the attachment disk 140 to tilt up and down. Two retractable tabs 142 extend from the edges of the attachment disk 140 , to help hold the attachment disk to the rigid core 210 of the tablet housing 200 , as is described in more detail below in connection with FIG. 7 . The retraction buttons 144 (only one shown in FIG. 2 ) that are located proximal to the retractable tabs 142 operate to retract the tabs 142 whenever the buttons 144 are pressed inward. Springs within the headrest coupling 100 re-extend the tabs 142 and the buttons 144 when pressure is removed from the buttons 144 .
[0022] The tablet housing 200 is shown with a tablet computer 250 held in place by the flexible rim 220 of the tablet housing 200 . The tablet computer 250 can be any relatively flat device with a display screen that can be used in a vehicle to present entertainment programming, play games, or run applications. Examples of existing tablet computers 230 include the Apple iPad devices (from Apple Inc. of Cupertino, Calif.) and tablet computers running the Android operating system from Google Inc. (Mountain View, Calif.). The tablet 250 is inserted into the tablet housing 200 by stretching the flexible rim 220 around the circumference 252 of the tablet 250 , as shown in FIG. 3 . During normal insertion, one side of the tablet 250 is first positioned within the flexible rim 220 so an inward facing ridge 224 on the rim 220 extends slightly over the front face 254 of the circumference 252 of the tablet computer 250 . The final corner 226 of the flexible rim 220 is then stretched around the last corner of the tablet 250 , ensuring that the tablet is securely held by the tablet housing 200 . The rubber or rubber-like consistency of the flexible rim 220 helps protect the tablet computer 250 in case of accidental drops, even if the tablet 250 were to fall flat on its face 254 . In addition, the flexible rim 220 provides a comfortable grip for users when the combination tablet 250 and tablet housing 200 are used in hand-held mode separated from the headrest coupling 100 .
[0023] In other embodiments, the flexible rim 220 is replaced by any known technique for securing a tablet computer 250 , such as straps, elastic bands, moveable bars, and the like. In these embodiments, the headrest coupling 100 may still attach to the tablet housing 200 through the rigid core 210 . It is not necessary that the tablet computer 250 be secured by stretching the elastic rim 220 around the computer as long as some attachment mechanism is used by the tablet housing 200 to secure the tablet 250 .
[0024] FIG. 4 shows the process that is used to attach the headrest coupling 100 to the posts 320 of the vehicle headrest 310 . The locking clips 130 are released, allowing the hinged arms 110 to open. The arms 110 open wide enough to allow the arms to pass between the two headrest poles 320 while the headrest coupling 100 is moved forward below the headrest 310 , as indicated by the arrow 400 in FIG. 4 . Once the body 120 of the headrest coupling 100 is adjacent the poles 320 , the hinged arms 110 are closed around the poles 320 as indicated by arrows 402 . When the arms 110 are closed, the locking clips 130 are used to secure the arms 110 in a closed position. Each locking clip 130 has a projection 132 that is received in an indentation (not shown) on the hinged arm 110 . This prevents that portion of the clip 130 from moving with respect to the hinged arm 110 during the locking action. On the opposite end of the clip 130 from the projection 130 is the base portion 134 of the locking clip. The base portion 134 is sized and positioned to be received by an engaging depression 126 in the base 120 of the headrest coupling 100 . As shown in FIG. 5 , the hinged arm 110 is held closed by the projection 132 of the clip, while the based is pulled over (arrow 500 ) to be received by the engaging depression 126 . The closed clip 130 is shown in FIG. 6 . Preferably, the natural opening between the toothed gripping surface 112 on the hinged arm 110 and the toothed gripping surface 112 on the base 120 of the headrest coupling 100 is sized to be smaller than most or all anticipated headrest posts 320 . In this way, the gripping surfaces 112 will be compressed against the post 320 , preventing the post 320 from moving relative to the headrest coupling 100 when the clip 130 is closed. The clip 130 can be unlocked by simply pushing the base portion 134 away from the body 120 of the headrest coupling 100 .
[0025] The mechanism for attaching the headrest coupling 100 to the tablet housing 200 is shown in FIG. 7 . As described above, the headrest coupling 100 has a rigid core 210 preferably constructed of hard plastic. The front portion of this core 210 shown in FIG. 1 includes a plurality of flanges 212 that help secure the rigid core 210 to the flexible rim 220 . The rear portion of the core 210 has a circular wall 230 as shown in FIG. 7 . This circular wall 230 surrounds a circular cavity 232 . The back surface 234 of the cavity 232 is still part of the rigid core 210 . Along the circular circumference of cavity 232 is a circular track 236 , which is essentially a thin, uniform indentation or channel in the wall 230 of cavity 232 . The track 236 is located approximately halfway into the cavity 232 .
[0026] The attachment disk 140 of the headrest coupling 100 also has a circular shape, and is designed to be received within the circular cavity 232 of the rigid core 210 of the tablet housing 200 . When the retraction buttons 144 are pushed, the tabs 142 of the attachment disk 140 are retracted, and the attachment disk 140 may then be inserted into the cavity 232 . This is shown in FIG. 8 , where pressing of the buttons 144 (arrow 800 ) causes retraction of the tabs (arrow 802 ), thereby allowing the attachment disk 140 to be inserted into the cavity 232 of the tablet housing 200 (arrow 804 ).
[0027] When the retraction buttons 144 are released, the retractable tabs 142 re-extend into the track 236 of the circular wall 230 . The engagement between the tabs 142 and this track 236 prevents the headrest coupling 100 from being removed from the tablet housing 200 until the retraction buttons 144 are pressed again. This engagement is shown in FIG. 9 , where the attachment disk 140 has been successfully inserted into the cavity 232 , with the retractable tabs 142 extended into the circular channel 236 .
[0028] In the preferred embodiment, the track 236 extends along the wall 230 more than is necessary to receive the length of the retractable tabs 142 . This allows the tablet housing 200 to be rotated with respect to the headrest coupling 100 , with the tabs 142 sliding within the tracks 236 without danger of the tabs 142 falling out of the tracks 236 and decoupling the attachment disk 140 from the tablet housing 200 . To assist in this rotation, the tabs 142 have an arcuate shape that is shaped to match the inner diameter of the track 236 . In the preferred embodiment, the track 236 does not extend through the whole circumference of the circular wall 230 uninterrupted. This means that the tablet housing 200 may not rotate completely when attached to the attachment disk 140 of the headrest coupling 100 . Instead, stops within the tracks 236 (or the end of the track 236 itself) limits this rotation to ninety degrees. By careful placement of the stops or ends of the track, the rotation is preferably bounded by positions where the rectangular tablet housing 200 is presented in horizontal and vertical positions relative to the elongated body 120 of the headrest coupling 100 . Careful manufacture of the track 236 also allows a frictional engagement at these two positions, thereby preventing drift or accidental movement away from the horizontal or vertical positions while still allowing rotation when desired by the user. This is shown in FIG. 10 , wherein the tablet housing 200 is shown in a vertical position with respect to the headrest coupling 100 , and arrows show how the tablet housing 200 can be rotated into a horizontal position (shown in phantom).
[0029] In one embodiment, the attachment disk 140 is connected to the body 120 of the headrest coupling 100 through a hinge 150 . As shown in FIG. 11 , the hinge 150 allows the tablet housing 200 and the tablet computer 250 to tilt upward and downward when the tablet housing 200 is mounted to the headrest coupling 100 .
[0030] One advantage of attaching the headrest coupling 100 to the tablet housing 200 through the attachment disk 140 and circular cavity 232 is the ease with which the two components 100 , 200 can be separated. Even after mounting in a vehicle, a user can simply press the retraction buttons 144 and pull the tablet computer 250 and tablet housing 200 off of the headrest coupling 100 . Since the tablet housing 200 takes the form of a protective cover for the tablet computer 250 , the tablet 250 can comfortably be used in the user's hands or lap without removing the tablet 250 from the tablet housing 200 . Temporary handheld use is therefore possible. When the tablet 250 needs to be remounted, the retraction buttons 144 are pressed, and the tablet housing 200 is reattached to the attachment disk 140 .
[0031] The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims. | A device and method is presented that attaches a tablet computer to a vehicle headrest. A two-piece mount has a headrest coupling and a tablet housing. The tablet housing has a rigid core attached to a flexible rim portion that secures the tablet computer within the tablet housing. The rigid core has a circular cavity in the rear. The headrest coupling mounts to headrest posts in a vehicle using hinged arms and locking clips. The headrest coupling further has a circular attachment disk that fits within the circular cavity of the tablet housing. Retractable tabs in the circumference of the attachment disk fit within tracks in the walls of the circular cavity. The tabs prevent accidental separation of the tablet housing from the headrest coupling, and allow rotation of the tablet housing when attached to the headrest coupling. | 8 |
BACKGROUND OF THE INVENTION
This invention is directed to a system and method for selecting a business location, wherein the business location has an activity level indicator. More particularly, this invention is directed to a system and method for directing customers to a selected business location based on the business activity level of the establishment. In particular, a potential customer receives an indication as to the business activity level, such as customers in line, average wait time, and the like, of selected establishments allowing the customer to select the establishment that offers the most efficient service.
Customers often use store or service establishment locators to find the locations of the stores or services in a selected geographic area. Such store or service locator is typically implemented as a web application or web service. A customer is generally able to identify available service locations within the selected geographic area based on criteria specified by the customer. The customer will then select the most convenient location. Additional information about each location may be provided, such as operating hours, types of services available, and directions.
However, current store or service locators do not provide any real-time information which would assist the customer in selecting a particular location. It would be desirable for a customer to have information about the current activity level of each location, such as the number of customers in line, the average wait time, operating hours, and the like. If the customer were to have such information, the customer would be able to select the most accessible location in the selected geographic area with the fewest customers or the shortest waiting time. As current store or service locators do not provide such information, the customer will randomly pick a location based on criteria other than business activity level of the location, such as the services offered or proximity to the customer. The selected location may be very busy and the customer will have a long wait or will decide to go to another location. It would be desirable to have a store or service locator which provides real-time information as to the business activity at each location.
The subject invention overcomes the aforementioned problems and provides a system and method for directing customers to a business location or establishment.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a system and method for selecting a business location, wherein the business location has an activity level indicator.
Further, in accordance with the present invention, there is provided a system and method for directing customers to a selected business location based on the business activity level of each establishment.
Still further, in accordance with the present invention, there is provided a system for selecting a business location, wherein the business location has an activity level indicator. The system includes means adapted for receiving a query from an associated user. The query represents a desired purveyor, or service center of selected goods and/or services in a selected geographic area. The system further includes means adapted for securing data representing a set of purveyors of the selected goods and services in the selected geographic area. The system also comprises means adapted for acquiring business activity data for each purveyor of goods or services in the set. The system further comprises means adapted for generating a business activity level signal. The signal represents the level of business activity for each purveyor in the set. In addition, the system includes means adapted for communicating the set of purveyors data and each corresponding business activity signal to the associated user.
In a preferred embodiment, the system also includes means adapted for generating a color signal representing the business activity level signal, and means adapted for generating ranking information corresponding to the business activity level for each purveyor. In one embodiment, the system further comprises means adapted for communicating the data via at least one of a wireless network data connection and a wired network data connection.
Yet further, in accordance with the present invention, there is provided a method for selecting a business location, wherein the business location has an activity level indicator. A query is received from an associated user representing a desired purveyor of a selected good or service in a selected geographic area. Data is then secured representing a set of purveyors of the desired goods or services in the selected geographic area. Business activity data is then acquired corresponding to business activities for each of the purveyors in the set. A business activity level signal is then generated to represent the level of business activity for each purveyor in the set. This data is then communicated to the associated user.
In a preferred embodiment, a color signal representing the business activity level signal is generated and ranking information corresponding to the business activity level of each purveyor is ascertained. In one embodiment, the query for a purveyor is transmitted over a wireless data communications channel.
Still other aspects of the present invention will become readily apparent to those skilled in the art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the best modes best suited for to carry out the invention. As it will be realized, the present invention is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without from the invention. Accordingly, the drawing and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description server to explain the principals of the invention. In the drawings:
FIG. 1 is a block diagram illustrative of a system in accordance with the present invention;
FIG. 2 is a flowchart illustrative of a method in accordance with the present invention; and
FIG. 3 is a template screen shot illustrative of one embodiment of the present invention.
These and additional embodiments of the invention may now be better understood by turning to the following detailed description wherein an illustrated embodiment is described.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is directed to a system and method for selecting a business location, wherein the business location has an activity level indicator. More particularly, the present invention is directed to a system and method for directing customers to a selected business location based on the current business activity level of the establishment. FIG. 1 is a system diagram illustrating a system 100 in accordance with the present invention. The system 100 comprises a computer network, illustrated in FIG. 1 as the Internet 102 . Those skilled in the art will appreciate that other computer networks, including, without limitation, Wide Area Networks, Local Area Networks and the like, are equally capable of embodying the subject invention. The system 100 also includes one or more purveyor, or service, locations, illustrated in FIG. 1 as service center (A) 104 , service center (B) 106 and service center (C) 108 .
In the preferred embodiment, service centers 104 - 108 of the present invention suitably comprise one or more image generating devices (not shown). However, it is to appreciated that the subject teachings are suitably used in connection with any service provider, distributor or retailer for which accurate information as to ongoing business activity is advantageously provided to an actual or potential consumer. It is to appreciated that “service center,” as used herein is equally applicable to all such establishments. The one or more image generating devices are any suitable devices known in the art that are capable of generating image outputs in a tangible medium, such as a printer, facsimile machine, scanning device, copier, multifunctional peripheral device, or other like peripheral devices. The image generating devices are any suitable networked image generating devices as will be appreciated to one of ordinary skill in the art. The image generating devices preferably have an internal device controller suitably acting as a fully functional server with the necessary hardware and software that ensure proper operation of the image generating device as will be appreciated by those skilled in the art. In addition, the image generating devices preferably comprise accessible storage mediums, which are suitably a hard disk and random access memory as will be appreciated by those skilled in the art. Such storage medium is suitably integrated into the image generating device or disposed in an associated medium associated therewith. Suitable commercially available image generating devices include, but are not limited to, the Toshiba e-Studio Series Controller.
Each center 104 - 108 , and through them, each image generating device, is suitably connected to a data network, which in the preferred embodiment includes the Internet 102 as is known in the art. The system also includes one or more user devices for locating and displaying to a user the location of a center 104 - 108 in accordance with the present invention. As shown in FIG. 1 , user devices include a smart phone 110 , a laptop computer 112 , a PDA 114 , a desktop computer 116 and a web-enabled cellular telephone 118 . However, it is to be appreciated that the subject system contemplates and teaches any data device accessible by a user in connection with assessment of real time, or near real time, information relating to site choice for securing product or services. The system is particularly advantageous when used in conjunction with portable data devices, such as those representative devices listed above. While the use of the Internet maintains the current advantage of widespread adoption and connectivity, it is be appreciated that any suitable, commonly accessible network, accommodates the data connectivity reflected herein. The user devices 110 - 118 suitably comprise components, as known in the art, to enable them to communicate with the Internet 102 . Each of the user devices 110 - 118 suitably include display means adapted to display graphical location content representative of the service centers 104 - 108 received via the Internet 102 . Service center 104 - 108 locations and maps corresponding thereto are suitably stored in a database 120 in data communication with the user devices 110 - 118 via the Internet 102 .
As will be understood by those skilled in the art, the user devices 110 - 118 are adapted to communicate with the service centers 104 - 108 via any wired or wireless data communications channels. In the preferred embodiment, user devices 110 - 114 , and 118 access the Internet 102 via wireless data communications, including without limitation, IEEE 802.11x, WiMax, Bluetooth, cellular, optical, infrared, and the like. Via such communications channels, the user devices 110 - 114 , and 118 effectively communicate with map database 120 and the web-based service locator of the present invention. In addition, the aforementioned wireless communications channels are capable of being implemented via the desktop 116 having a suitable wireless interface adapter. Alternatively, all user devices 110 - 118 are capable of accessing the Internet using Ethernet, Token Ring, or other local- or wide-area type networks, without departing from the spirit and scope of the present invention.
The system described above will best be understood in combination with the flowchart 200 of FIG. 2 , which illustrates a method in accordance with the present invention. Turning now to FIG. 2 , the method of the present invention illustrated in flowchart 200 begins at step 202 when a service center locator request is received from an associated user via one of the user devices 110 - 118 running a service locator application. The skilled artisan will appreciate that the present invention is described in reference to a web-based service locator application, however other means of providing the services described herein are equally capable of being implemented without departing from the scope of the present invention. In the preferred embodiment, the service center locator is a web-based application, or service, suitably adapted to provide to the associated user real-time data representing the business activities, locations, driving directions and the like, corresponding to service center 104 - 108 locations.
Once the location request has been submitted, the method proceeds to step 204 , wherein the associated user inputs his present location using any means known in the art. For example, the associated user enters a GPS signal received by the smart phone 110 , the PDA 112 , the laptop 114 or the cellular telephone 118 through the integrated input device associated with each respective user device. Alternatively, the associated user, at the desktop computer 116 , suitably enters his address and zip code via any means known in the art. The associated user is then prompted, at step 206 , to input a desired search radius. The search radius refers to a distance from the user's present location to a service center 104 - 108 . For example, service center (A) 104 , service center (B) 106 , and service center (C) 108 , are each located within the specified search radius. The service locator application then queries the map database 120 and generates a listing of service centers 104 - 108 located within the designated search radius, including the exemplary service centers (A-C) 104 - 108 .
The service locator application then retrieves, at step 210 , business activity data for the first service center, or purveyor, location in the list. The business activity data suitably includes information corresponding to the number of customers in the store, the traffic on the route to the store, the estimated waiting time for access to the one or more image generating devices, and other indicia of business activities taking place at the service center location. The business activity data suitably also includes information relating to whether the service center is currently open or if the service center is located at a distance such that travel time required to reach the service center would result in the service center being closed when the user arrived at the service center. The skilled artisan will appreciate that the data is suitably gathered at the service center location using any means known in the art and suitably retrieved via the Internet 102 from the service centers 104 - 108 . Using FIG. 1 as an example, the service locator application retrieves real-time business data from service center (A) 104 . This data is then used to generate a business activity level at step 212 corresponding to the level of activity taking place, in real-time, at service center (A) 104 .
The service locator application then generates a suitable indicia, such as a color code, numeric value, graphical indicator or brightness level to represent the level of business activity at service center (A) at step 214 . As will be appreciated by those skilled in the art, use of indicia such as the color code provides a visual representation to the user of the level of activity more readily than pure textual information. The service locator application then ranks, at step 216 , service center (A) 104 according to the business activity level determined at step 212 . A determination is then made at step 218 whether any additional service centers 104 - 108 are located within the specified search radius. Such radius is suitably specified by a user, or alternatively set to a default value. It is to be appreciated that the subject system includes a combined radius wherein a default is preset, and is selectively overridden by user input relating to a particular user's situation. When an additional service center, service center (B) 106 , is located within the specified search radius, the method returns to step 210 , wherein business activity data is retrieved from service center B 106 . The retrieved data from service center (B) 106 is then used to determine corresponding indicia, such as the color code and rank of the preferred embodiment. This process is repeated for all service centers 104 - 108 located within the specified search radius, e.g., service center (C) 108 . As discussed above, business data associated with service centers which are closed or will be closed when the user is due to arrive at a service center will be retrieved and a suitable indicia for services centers will be generated.
When it is determined at step 218 that no additional service centers 104 - 108 are located within the specified search radius, the method proceeds to step 220 , wherein a map is generated illustrating the location of each located service center 104 - 108 . The skilled artisan will appreciate that the map is suitably generated using map or other geographic data contained in the map database 120 via any means known in the art, which map data is suitably retrieved from an associated user device, or from a remote location via communication from the network, such as the Internet 102 ( FIG. 1 ). Each service center 104 - 108 location is suitably displayed on the map and associated with the color code and ranking data at step 222 . The generated map with associated color and ranking data is then transmitted via the Internet 102 and displayed on the user devices 110 - 118 at step 224 . In one embodiment of the present invention, the user devices 110 - 118 receive a color coded listing containing the associated color and ranking data of the service center locations 104 - 108 . The color coded list is suitably capable of being displayed at step 224 on the map screen, or on a separate screen on the user devices 110 - 118 . In either display, the list contains service center location 104 - 108 ranking data and is color coded as set forth above.
FIG. 3 illustrates a representative template screen 300 , suitably displayed to the associated user on a user device 110 - 118 . As set forth above, in one embodiment, the present invention is implemented as a graphical user interface, which graphical user interface is a web-based application in the preferred embodiment. Screen 300 suitably depicts a web browser, viewable on the user devices 110 - 118 ( FIG. 1 ). The web browser is any browser known in the art including, without limitation, Internet Explorer, Netscape Navigator, Mozilla, FireFox, Opera and the like. As illustrated in FIG. 3 , the address of a web site corresponding to one implementation of the present method is shown in the address bar 302 . Once the service locator screen 300 has been displayed, the associated user enters his present address in the present address field 304 . The associated user then selects, from the search radius pull-down menu 306 , the maximum distance from the present location the user is willing to travel to a service center. The user is also prompted to select, from the store type pull-down menu 308 , the type of service center desired, e.g., copy center, email center, and the like. Once this information has been entered, the service locator retrieves service center information in accordance with the method described above, and displays the map 310 on the screen 300 .
The associated user is able to zoom in and out of the displayed map 310 using the zoom slide 312 located on the screen 300 . The scale of the map 314 is also displayed and editable by the user to adjust the scale of the map without using the zoom slide 312 . As explained above, the map 310 suitably displays color coded and ranked service center 104 - 108 location information. Referring to the map 310 of service centers 104 - 108 within the search radius 306 , an indicator icon 316 is illustrated depicting the present location of the user. Also shown on the map 310 are numeric icons 320 - 326 illustrating the location of the service centers found within the input search radius. Each numeric icon 320 - 326 corresponds to the rank of the center versus the other centers found. Alternatively, the rank corresponds to a predetermined ranking structure, based upon one or more preselected factors, such as distance, traffic, travel time, type of work, pending jobs, relative costs and the like. Continuing with the example of FIG. 1 , the map 310 displays five service centers located within the search radius, service centers ( 1 - 5 ) 318 - 326 , respectively. For purposes of explanation, service center ( 1 ) 318 corresponds to service center (A) 104 , service center ( 2 ) 320 corresponds to service center (B) 106 , and service center ( 3 ) 322 corresponds to service center (C) 108 . Service centers ( 4 ) and ( 5 ) 324 and 326 , respectively, represent other service centers found within the search radius.
Each numeric icon 318 - 326 is color coded to illustrate an initial description of the current level of business activity at the corresponding service center. The present invention enables the user to highlight an icon and, by double-clicking the numeric icon, view additional details about the corresponding service center. As shown in FIG. 3 , the pointer is on service center ( 4 ) 324 . While on center ( 4 ) 324 , a text window 328 is displayed prompting the user to double-click for additional information. In an alternate embodiment, the text box 328 contains additional information, such as wait time per machine, number of imaging jobs pending, number of customers on the premises, and the like. The user is then able to view such information for each service center, if desired, and intelligently select the service center meeting his specific constraints.
Once the user has selected the desired center, he is able to retrieve, from the map database, readable driving directions by selecting the driving directions button 330 . Should the user desire a different search, he is able to begin a new search via new search button 332 , or exit the present search via exit button 334 . Thus, when the user determines that service center (B) 106 has the fewest pending jobs and least number of customers, ranked number ( 2 ) on the map 310 , the user double-clicks the icon 320 representing service center (B) 106 to select the service center for further distinction. Upon selection, the driving directions button 330 advantageously becomes highlighted, as is known in the art, and the user is able to press the directions button 330 and view a screen (not shown) containing detailed text driving instructions. The skilled artisan will appreciate that the aforementioned map 310 is suitably displayed on any one of the user devices 110 - 118 via any suitable connection to the Internet 102 . It is to be further appreciated that the information thus made available is suitably used in conjunction with a navigation system that allows updated travel, direction and routing information as a user approaches a selected service center. The subject system also allows a user to continue to monitor available service centers during transit to allow for modification to a substitute service center should situations such as business level or routing concerns, such as traffic, detours or hazards, alter a previously establishment.
The invention extends to computer programs in the form of source code, object code, code intermediate sources and object code (such as in a partially compiled form), or in any other form suitable for use in the implementation of the invention. Computer programs are suitably standalone applications, software components, scripts or plug-ins to other applications. Computer programs embedding the invention are advantageously embodied on a carrier, being any entity or device capable of carrying the computer program: for example, a storage medium such as ROM or RAM, optical recording media such as CD-ROM or magnetic recording media such as floppy discs. The carrier is any transmissible carrier such as an electrical or optical signal conveyed by electrical or optical cable, or by radio or other means. Computer programs are suitably downloaded across the Internet from a server. Computer programs are also capable of being embedded in an integrated circuit. Any and all such embodiments containing code that will cause a computer to perform substantially the invention principles as described, will fall within the scope of the invention.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. | A method for directing customers to a business establishment. A query is received from an associated user representing a desired purveyor of a selected good or service in a selected geographic area. Data is then secured representing a set of purveyors of the desired goods or services in the selected geographic area. Business activity data is then acquired corresponding to business activities for each of the purveyors in the set. A business activity level signal is then generated to represent the level of business activity for each purveyor in the set. This data is then communicated to the associated user. | 6 |
BACKGROUND OF THE INVENTION
[0001] This invention is related to a process for making electrospun fibers by controlling the vapor pressure of the process.
[0002] The electrospinning process uses electrical force to produce nanofibers. A charged droplet acquires a conical shape known as a Taylor cone and then becomes unstable. A charged jet ejects from a vertex and developes a spiral path due to the electrically driven bending instability, making it possible for the jet to elongate by a large amount and produce nanofibers in a small space.
[0003] Electrospinning is receiving attention due to its cost effectiveness and the straightforward route to nanofibers. Electrospun fibers and electrospinning processes have many potential applications including filtration, biomedical application, fuel cells, solar sails and composites. Many polymer and ceramic precursor nanofibers have been successfully electrospun with diameters in the range from 1 nm to several microns.
[0004] The process of electrospinning generally involves the creation of an electrical field at the surface of a liquid. The resulting electrical forces create a jet of liquid which carries an electrical charge. Thus, the liquid jets may be attracted to other electrically charged objects at a suitable electrical potential. As the jet of liquid elongates and travels, it hardens and dries. The hardening and drying of the elongated jet of liquid may be caused by cooling of the liquid, i.e., where the liquid is normally a solid at room temperature; evaporation of a solvent, for example, by dehydration, (physically induced hardening); or by a curing mechanism (chemically induced hardening). The produced fibers are collected on a suitably located, oppositely charged receiver and subsequently removed from the receiver as needed, or directly applied to an oppositely charged generalized target area.
[0005] The electric force causes the jet to emerge from a Taylor cone. The charged jet of polymer solution elongates and moves toward the collector in a straight line for a distance, and then begins to bend and develop a spiral path. The repulsive force between charges carried by the jet causes the jet to elongate and thin. The elongation and thinning of the charged jet continue until solidification occurs. Many factors affect the fiber diameter and morphology. Both intrinsic solution properties, including viscosity, concentration, surface tension, relaxation time, and processing parameters, including applied potential, distance from polymer droplet to grounded collector, size of orifice and temperature affect the fiber diameter and morphology.
[0006] Many attempts have been made to control the diameter of the nanofibers. Fridrikh et al. did not mention the partial pressure of the solvent as a control parameter. Lee et al., in their conclusions, suggested that “there was an optimum electric current value for obtaining uniform high quality nanofibers when . . . ” salt was added to the solution. Tan et al. reported on the effects of polymer concentration in the solution, molecular weight of the polymer, electrical conductivity of the solvent, the electrical voltage used, and the feed rate of the fluid to the process. They concluded the polymer concentration, the molecular weight, and the electrical conductivity were the dominant parameters, but made no mention of the ambient atmosphere.
[0007] Yarin proposed a mathematical model to calculate jet path and fiber diameter during the electrospinning process. The mathematical model being based on the balance of forces acting on the charged jet, including the Coulombic force between charges carried with the jet, force from the electric field, surface tension force, and viscoelastic force. Two publications regarding mathematical models were reported, the first without evaporation and solidification, and the second including evaporation and solidification. Results from the mathematical model without evaporation showed the charged jet continues to elongate indefinitely. When the effect of evaporation and solidification were accounted for in the calculation, a quantitative agreement between experiment and calculation was formed. Evaporation of the solvent changes the viscoelastic properties of the polymer solutions, gradually making it harder for the charged jet to elongate.
SUMMARY OF THE INVENTION
[0008] The present invention is to a process and apparatus for making electrospun fibers by controlling the vapor pressure of the process. The process of forming electrospun fibers including the steps of supplying a substantially homogeneous mixture of a solvent and a polymer which can be formed into an electrospun fiber; electrospinning the polymer into a fiber in an enclosed chamber; monitoring the humidity in said chamber; and changing the partial pressure of solvent evaporation to thereby modify the morphology of the thus formed fibers. The fibers can be produced with controlled diameters, and can result in fibers having smaller diameters than are normally achieved in an electrospinning process. The present process can control the balance between the formations of beads, branches, ribbons, and surface skins that may lead to ribbons and garlands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] 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.
[0010] FIG. 1 is a perspective view of an apparatus for use in the present process;
[0011] FIG. 2 details scanning electron micrographs of the poly(ethylene oxide) nanofibers elecrospun in air at 5.1% to 63.5% relative humidity;
[0012] FIG. 3 is a graph detailing the average fiber diameter as a function of relative humidity;
[0013] FIG. 4 is a graph detailing the average bead diameter, bead length and distance between beads at different relative humidity; and
[0014] FIG. 5 is an optical micrograph of poly(ethylene oxide) electrospun from aqueous solution under (a) 8.8%, (b) 20.7%, (c) 40.8%, and (d) 57.3% relative humidity.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present process involves the control of the evaporation of the solvent used to make the fibers, and in turn the associated solidification and formation of the fibers. These factors also determine the diameter of the electrospun nanofibers. The elongation and thinning of a charged jet stops when the charged jet is solidified. The evaporation and solidification of the charged jet are controlled by varying the partial pressure of the solvent during electrospinning.
[0016] The invention will be explained in the context of a water borne polymer, where the partial pressure of the water vapor of poly(ethylene oxide) from aqueous solution is controlled. As the partial pressure of water vapor increases, the solidification process of the charged jet becomes slower, allowing elongation of the charged jet to continue and thereby form thinner fibers.
[0017] The present process is not limited to aqueous solvent products. The process applies to most polymers electrospun from solution. In the process example, the rate of solvent evaporation and the solidification of a charged jet were controlled during electrospinning of poly(ethylene oxide) in aqueous solution. The evaporation rate of the solvent, in this case water, was controlled by changing the partial pressure of water vapor in the air surrounding the jet. The decreased evaporation rate of solvent from the jet allows the charged jet to remain fluid, continue to elongate, and become thinner.
[0018] The apparatus for practicing the process of the present invention is shown in FIG. 1 . The basic electrospinning apparatus is known and is disclosed in U.S. Pat. Nos. 6,110,590 and 6,753,454, the disclosures of which are incorporated herein by reference.
[0019] The apparatus consists of an electrospinning apparatus 10 in an enclosed chamber 12 , which allows the humidity of the chamber to be measured and controlled. The electrospinning apparatus 10 consists of a polymer reservoir 14 which supplies a uniform mixture of solvent and fiber forming polymer to the electrospinning apparatus. The fiber is drawn from the outlet from the polymer supply reservoir 14 by the electrical force created by the electrical potential supplied by power supply 16 which creates a differential between reservoir 14 and a fiber collector 18 . As noted earlier, the electrospinning apparatus is known in the art.
[0020] The enclosed chamber 12 allows for the control of the vapor pressure of the solvent employed in the process and thus the morphology of the fibers that are formed. The enclosed chamber employs a humidity sensor 20 , such as a hygrometer, to provide a measurement of the humidity. A humidifying device 22 , such as a wick or ultrasonic humidifier, is employed to increase the humidity in the chamber, while a cooling device 24 is employed to lower the humidity. A fan 26 is employed to circulate the air in the chamber and provide uniform distribution of the humidity. In the case of other electrospinning processes, where the solvent may be an organic solvent or alcohol, the vapor pressure may be controlled by injecting the solvent into the chamber to increase the vapor pressure and by selective absorption of the solvent vapor to reduce the vapor pressure. Furthermore, the ambient gas in the chamber can be air or any inert gas such as nitrogen or argon. The possibility that the concentration of an organic solvent, required for control, in air can raise issues of working with an explosive mixture, and for safety reasons should always be avoided. Alternative non-flammable solvents may be available, and in cases were a flammable solvent is essential, the ambient air can be replaced with an inert gas.
Experimental
[0021] Poly(ethylene oxide) with molecular weight of 400,000 g/mol obtained from Scientific Polymer was used. The aqueous solution of poly(ethylene oxide) was prepared at room temperature at concentration of 6% by weight. The solution was electrospun in a closed chamber in which the relative humidity during the electrospinning process was controlled. FIG. 1 shows the arrangement used in this study. An ultrasonic humidifier and dry ice, as the cooling device, were used to increase or decrease humidity in the chamber. Circulation of water vapor was maintained by a fan. Poly(ethylene oxide) aqueous solution was held in a glass pipette, that was connected to a high voltage power supply. A flat metal collector was placed 18 cm below tip of the glass pipette. The applied potential difference between the top and the collector was 5 kV. Current, temperature and humidity of the air in the chamber were monitored during the electrospinning process. The humidity and temperature sensor used in this experiment was HTM 1505 (±0.2% RH, ±0.5° C.) manufactured by Humerel.
[0022] Morphological features of the electrospun fibers were observed with a scanning electron microscope, a JEOL model JSM-7401F and with an Olympus model DP70 optical microscope.
[0023] The average fiber diameter, bead diameter, bead length, distance between beads were obtained by using image analysis software version 3.0.1.0, available from Digimizer. The measurement was done at every 2 micron length of 10 segments. The total number of data points for each sample was about 50.
[0000]
TABLE 1
Relative humidity, temperature, and the average fiber diameters
Relative humidity
Temperature
Average fiber diameter
(%)
(° C.)
(nm)
5.1
21.0
253 ± 24
8.8
21.0
249 ± 26
20.7
21.4
223 ± 24
30.6
21.6
231 ± 23
40.8
22.0
160 ± 15
48.7
22.2
144 ± 16
52.6
22.4
132 ± 23
57.3
23.2
103 ± 27
58.9
23.2
80 ± 17
61.2
23.2
77 ± 17
63.5
23.2
63 ± 16
Note:
Humidity inside chamber at each data point was kept at ±0.4% RH. The observed current flowing from the tip was constant around 400 nA.
[0024] FIG. 2( a )-( g ) shows scanning electron micrographs of poly(ethylene oxide) nanofibers elecrospun in air from an aqueous solution at (a) 8.8%, (b) 20.7%, (c) 40.8%, (d) 52.6%, (e) 57.3%, (f) 61.2% and (g) 63.5% relative humidity. The 5.1% to 63.5% range of relative humidity, as reported in Table 1, resulted in the average diameter of poly(ethylene oxide) nanofibers gradually decreasing from around 253 nm when electrospun at 5.1% relative humidity to around 63 nm when electrospun at 63% relative humidity.
[0025] FIG. 3 shows the average fiber diameter as a function of relative humidity. The charged jet solidified at the largest diameter when electrospun at low humidity since water in the jet evaporated rapidly. When the charged jet becomes very thin, the charges carried by the jet move further apart. The surface area increases, and the charge per unit area on the surface of the jet decreases. The development of the capillary instability creates thin fiber segments between beads with diameter larger than the fiber. Beaded fibers appeared at 51% relative humidity and higher. The capillary instability of a fluid jet, which causes a cylindrical jet to break up into droplets, is a well known phenomenon. The surface energy of fluid in the form of a jet is higher than that of same volume of liquid in the form of drops. Several factors are known to affect the formation of beaded fibers. The volume of the beads relative to the volume of the fibers increased when electrospun under higher relative humidity. When the fibers were thinner, the bead diameter increased, the length of the beads decreased and the spacing between beads becomes smaller as shown in FIG. 3 and FIG. 4 , which shows the average bead diameter, bead length and distance between beads at different relative humidity.
[0026] The solid line in FIG. 3 shows the average fiber diameters at different relative humidity and it the linear fit of the average fiber diameter, ignoring the beads. The average fiber diameter decreased sharply when beads started to occur at 52.6% relative humidity. The total volume of polymer per unit length of the beaded fibers was calculated by adding the volume of the beads and the volume of the fibers, based on measurements of the images. The diameter corresponding to the volume per unit length is plotted as triangles in FIG. 3 . The apparent increase in the observed mass per unit length suggests that the beads growth shortens the length of the fiber segments between the beads.
[0027] The fibers were collected after the first electrical bending instability coils had grown to a diameter of about 100 mm. As seen in FIG. 5 , the optical micrograph of poly(ethylene oxide) electrospun from aqueous solution under (a) 8.8%, (b) 20.7%, (c) 40.8%, and (d) 57.3% relative humidity shows the fibers collected. No second or higher bending coils were seen when electrospun at low humidity as shown in FIG. 5 a . The more flexible jets electrospun at higher humidity developed higher orders of bending coils with diameters ranging from 100 mm to 0.05 mm. At the higher value of relative humidity, beads developed on the most segments of the fibers.
[0028] By controlling the evaporation and solidification affects, the fiber diameter of the fibers produced by the process can be controlled as well. By slowing evaporation and solidification, smaller fiber diameter fibers can be produced. Also, beaded fibers can be produced when the jet diameter is very thin and the charge per unit area is smaller. As such, the fibers produced by such a process can be thinner than those made by a traditional electrospinning process. The resulting fiber products will be more flexible and have a larger surface area per unit mass.
[0029] Electrospinning is widely used to make nanofibers for filtration. Other uses, for example, in biomedical applications are developing rapidly. During electrospinning an electrically charged jet is elongated by the repulsive force between electrical charges carried with the jet. The charged jet develops a spiral path known in the art, which makes it possible for the jet to elongate and produce nanofibers in a small space. Where the fibers are soluble, they can be used in products where the fibers are solubilized since the thinner fibers will dissolve faster. Still further, the thinning process results in orientation or alignment of the molecules in the regions that are thinned and provide beneficial tensile properties and/optical properties.
[0030] The process is also useful in making fibers having various shapes, including beads of various shapes, branches, and garlands. Such shapes have known utilities and could be used in filtration and catalysis applications.
THE FOLLOWING REFERENCES ARE HEREIN INCORPORATED BY REFERENCE
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[0042] Although the invention has been described in detail with reference to particular examples and embodiments, the examples and embodiments contained herein are merely illustrative and are not an exhaustive list. Variations and modifications of the present invention will readily occur to those skilled in the art. The present invention includes all such modifications and equivalents. The claims alone are intended to set forth the limits of the present invention. | A apparatus and process of forming electrospun fibers including the steps of supplying a substantially homogeneous mixture of a solvent and a polymer which can be formed into an electrospun fiber; electrospinning the polymer into a fiber in an enclosed chamber; monitoring the humidity in said chamber; and changing the partial pressure of solvent evaporation to thereby modify the morphology of the thus formed fibers. | 3 |
This invention relates to a process for producing fine spherical particles wherein the starting powder is passed through a powder port into a high temperature zone unobstructively by allowing one or more streams of gas to come into contact intermittently with the powder which has accumulated in the vicinity of the powder port to thereby keep this vicinity clear of powder. Processing can be carried out continuously without powder build up in the vicinity where the powder enters the high temperature zone.
BACKGROUND OF THE INVENTION
Fine spherical powders, especially alloy or elemental metal powders can be made by high temperature processing. Such processes are described in U.S. Pat. Nos. 3,909,241, 3,974,245, 4,592,781, 4,715,878, 4,502,885, 4,711,660 and 4,711,661.
One of the problems that occurs in this processing, especially plasma processing, is that powder tends to build up in the vicinity of the nozzle and powder port. This build up continues until the powder/carrier gas stream is effected and powder is not effectively injected into the plasma flame. This causes poor melting efficiency, thus decreasing the conversion efficiency to spherical powder. This build up can continue until the powder port is covered over and no powder is being injected into the flame. When any of these adverse occurrences are noted, the plasma processing system must be shut down temporarily to clean off the powder port/plasma nozzle area in order to effectively operate again. The plasma processing system is then started up again with this cycle repeating.
It would be a significant advance in the art to assure that powder is being injected consistently well into the flame by virtue of there being no partial or full blockages. Also, it would be a significant advance in the art if the plasma processing system could operate virtually continuously by virtue of not having to be shut down in order to clear off the powder port/plasma nozzle in order to remove fine powder build up.
SUMMARY OF THE INVENTION
In accordance with one aspect of this invention, there is provided a process for producing fine spherical particles from a fine powder feed material which comprises entraining the powder feed material in a carrier gas, introducing the feed material and carrier gas through a powder port into a high temperature zone and maintaining the powder feed material in the high temperature zone for a sufficient time to melt at least about 50% by weight of the particles of the powder and to form droplets therefrom while at the same time allowing one or more streams of gas to come into contact intermittently with any powder which has accumulated in the vicinity of the powder port to keep the vicinity clear of powder to allow the powder feed to pass unobstructively through the powder port into the high temperature zone. The droplets are then cooled to form spherical particles.
DETAILED DESCRIPTION OF THE INVENTION
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above description of some of the aspects of the invention.
The present invention provides a method for high temperature processing powder especially fine powder to produce spherical particles. The method results in the elimination of the problem of build up of powder in the vicinity of the powder port. By this vicinity is meant the powder port exit through which powder exits the powder port and enters the high temperature zone and the point of entrance of the heat from the high temperature source through which the heat such as a flame enters the high temperature zone to come in contact with the powder. The point of entrance of the heat and the powder port exit are in close proximity to one another usually about 1/4" from one another. The build-up occurs especially with fine powders. The build-up of power in the vicinity of the power port exit causes blockage preventing powder from entering the high temperature zone.
This invention is applicable to any powder material. However, it is especially suited to metal powders, and metal alloy powders, glass and ceramic powders.
The powder is entrained in a carrier gas such as argon, nitrogen and helium.
The powder entrained in the carrier gas is then passed through the high temperature zone and maintained in the high temperature zone at a temperature above the melting point of the powder for a sufficient time to melt at least about 50% by weight of the powder and form droplets therefrom. Some additional powder particles can be partially melted or melted on the surface and these can be spherical particles in addition to the melted portion. The preferred high temperature zone is a plasma.
As the powder exits the powder port and enters the high temperature zone through a powder port exit, one or more streams of gas are allowed to come in contact intermittently with any powder which has accumulated in the vicintiy of the powder port to clear the vicinity of the accumulated powder. In this way, the feed powder material passes unobstructively from the powder port into the high temperature zone. This is done by positioning one or more gas jets in the vicinity of the powder port and directed toward the powder port at the point of entrance of the heat into the high temperature zone. Preferably one jet is directed to a point adjacent to the actual point of entrance of the heat into the high temperature zone and in the vicinity of the powder port. Preferably the another jet is directed at the powder port itself. Usually the gas jets are positioned from about 1" to about 2" away from entrance point of the heat into the high temperature zone. This allows the gas stream or streams to essentially completely clear the powder port and heat entrance area of the accumulated powder. Gas is intermittently directed toward the normal area of powder build-up. The build up of powder, if any, is removed and the tendency toward obstructive build-ups is eliminated. The gas jets can be of any variety from a simple metal tube to a gas nozzle or blow off jet.
The gas can be of any nature according to the high temperature reaction that is desired but is generally inert. Some preferred gasses are argon, nitrogen and helium. The gas pressure can be generally low, for example, 50 psig or increased to be more effective, to -300 psig.
In accordance with a preferred embodiment in a plasma process, a ballast can be present in the gas line or lines prior to the gas jet nozzle in order to give higher volume during a short blast. The gas blasts are normally controlled by a solenoid valve in conjunction with a timer-relay. The valve normally opens and closes for about 0.5 second intervals over about a 5 second period every 10 minutes. These times can be adjusted over wide ranges as needed. The gas from the gas jet nozzle does disturb the injection of powder into the high temperature zone but the time when the gas is flowing is equivalent to about 0.5% if the run time so its effect on sphericity of the particles is minimal. A low flow of gas, ≦20 scfm is passed through the gas jet at all times. This is to eliminate the overheating and potential melting of the gas jet nozzle due to its proximity to the plasma flame. This low flow of gas does not interfere with the melting of the powder particles.
Details of the principles and operation of plasma reactors are well known. The plasma has a high temperature zone, but in cross section the temperature can vary typically from about 5500° C. to about 17,000° C. The outer edges are at lower temperatures and the inner part is at a higher temperature. The retention time depends upon where the particles entrained in the carrier gas are injected into the nozzle of the plasma gun. Thus, if the particles are injected into the outer edge, the retention time must be longer, and if they are injected into the inner portion, the retention time is shorter. The residence time in the plasma flame can be controlled by choosing the point at which the particles are injected into the plasma. Residence time in the plasma is a function of the physical properties of the plasma gas and the powder material itself for a given set of plasma operating conditions and powder particles. Larger particles are more easily injected into the plasma while smaller particles tend to remain at the outer edge of the plasma jet or are deflected away from the plasma jet.
As the material passes through the high temperature zone and cools, it is rapidly solidified. Generally the major weight portion of the material is converted to spherical particles. Generally greater than about 75% and most typically greater than about 85% of the material is converted to spherical particles by the high temperature treatment. Nearly 100% conversion to spherical particles can be attained. The major portion of the spherical particles are less than about 20 micrometers in diameter. The particle size of the plasma treated particles is largely dependent of the size of the starting powder material.
After cooling and resolidification, the resulting high temperature treated material can be classified to remove the major spheroidized particle portion from the essentially non-spheroidized minor portion of particles and to obtain the desired particle size. The classification can be done by standard techniques such as screening or air classification. The unmelted minor portion can then be reprocessed according to the invention to convert it to fine spherical particles.
Spherical particles have an advantage over non-spherical particles in injection molding. The lower surface area of spherical particles as opposed to non-spherical particles of comparable size, and the flowability of spherical particles makes spherical particles easier to mix with binders and easier to dewax.
To more fully illustrate this invention, the following non-limiting example is presented.
EXAMPLE
An argon-helium plasma flame is generated with a gas flow of about 30 l/min. Ar, and about 10 l/min. He with about 16.2 KW of input powder of about 360 amps and about 45 volts. Iron powder with about 40% by weight cobalt made from hydrometallurgical and hydrogen processing having a mean size of about 10 micrometers in diameter is introduced into the plasma flame at a rate of about 75 g/min. being fed by an argon carrier gas at a flow rate of about 3l/min. and being injected into the flame from a powder port. The powder is melted in flight rapidly solidified and collected in a chamber. Two blow off gas jet nozzles are mounted in the vicinity of, that is, about 1-2" away from the plasma gun nozzle, and the powder port exit into the plasma zone which are all in close proximity to one another, that is about 1/4" away from one another. One jet is positioned such that the gas exiting the jet is directed at the powder port exit and the other gas jet positioned such that the gas exiting the gas jet is directed at the face of the plasma nozzle. A flow of argon gas is passing through these gas jet nozzles continuously. This flow is about 10 l/min. and serves as a cooling gas to prevent the gas jet nozzles from melting. It has no effect on the process. Intermittently high flows of gas exit these gas jets. This serves to dislodge any powder build-up in the plasma nozzle/powder port vicinity that might inhibit injection of powder into the plasma flame. Selenoid valves operated by a timer relay open and close on 0.5 second intervals for a 5 second period every 10 minutes. The supply gas is normally at about 50 psig and the gas is delivered to the selenoid valve and to the blow off gas jet nozzle via 1/4" tubing. This procedure permits virtually continuous operation of the plasma process (usually a minimum of about 3-4 hours) whereas without them deleterious build-ups of powder necessitating shut-downs can occur as frequently as at 1/2 hour intervals.
While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | A process is disclosed for producing fine spherical particles from a fine powder feed material which comprises entraining the powder feed material in a carrier gas, introducing the feed material and carrier gas through a powder port into a high temperature zone and maintaining the powder feed material in the high temperature zone for a sufficient time to melt at least about 50% by weight of the particles of the powder and to form droplets therefrom while at the same time allowing one or more streams of gas to come into contact intermittently with any powder which has accumulated in the vicinity of the powder port to keep the vicinity clear of powder to allow the powder feed to pass unobstructively through the powder port into the high temperature zone. The droplets are then cooled to form spherical particles. | 1 |
FIELD OF THE INVENTION
The present invention relates to a device for mounting, removing and transporting of easily bendable curved objects with suspension edges, preferably printing plates, on and from a cylinder of a rotary printing press.
DESCRIPTION OF THE PRIOR ART
DE 28 04 970 A1 describes a device for mounting and removing printing plates in a rotary printing press.
In this case a suction element performs a linear movement between a delivery roller and a plate cylinder and in this way transports the printing plate.
This suction element is fastened by means of cylinders on a carriage driven by a chain. By means of this cylinder, the suction element can perform a tilting movement at right angles in respect to the carriage movement for lifting and lowering the printing plate. For assembly, the suction element fixes a beveled front edge of the printing plate in place by switching on the suction effect. The suction element together with the plate is lifted by means of the cylinder and moved in the direction toward the plate cylinder by the carriage with the chain drive. A positioning table is located between the delivery roller and the plate cylinder, on which the printing plate is placed and positioned. Thereafter, the suction element again picks up the printing plate and transports it to a groove of the plate cylinder. The beveled edge of the printing plate is inserted into this groove of the plate cylinder by lowering the suction element.
After the suction effect has been turned off, the plate cylinder turns together with the printing plate which is simultaneously wound off the delivery roller. Once the printing plate is almost completely wound off the delivery roller, the suction element grips a rear of the printing plate and guides it into a further groove of the plate cylinder.
It is disadvantageous in connection with this, device that it is necessary to deposit and position the printing plate on a positioning table which is located between the delivery cylinder and the plate cylinder. It is possible for tolerances, for example because of play in the carriage guidance, to occur during the transport of the printing plate from the positioning table to the cylinder and during the suspension process of the printing plate in the cylinder, which cause an erroneous axial position of the printing plate on the cylinder.
U.S. Pat. No. 4,727,807 A describes a device for mounting and removing printing plates in a rotary printing press. In this case, a manipulation device which picks up the printing plates is moved by a robot between a preparation device and a plate cylinder. Four suction grippers, by means of which the printing plate is held, are rigidly disposed on the manipulation device.
For assembly, the printing plate is moved from the preparation device to the plate cylinder by multi-axial movements of the robot and is suspended with a beveled edge in a clamping channel of the cylinder.
The axial positioning of the printing plate takes place via a drive which is regulated by means of force sensors. Subsequently, four pressure rollers are applied by pivoting the manipulation device. The printing plate is placed on the plate cylinder by rotating the plate cylinder and a further end is inserted into the channel.
It is disadvantageous with this device that the manipulation unit must be movable and pivotable in several directions in the radial plane of the plate cylinder and that complicated drives and controls are required for this. It is furthermore not possible to transport and mount or remove several printing plates per cylinder simultaneously.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a device for mounting, removing and transporting easily bendable, curved objects with suspension edges, preferably printing plates, whose respective legs form an angle of less than 90° and which have no recesses for register pins, without a device for pre-positioning, for example a positioning table, and without a robot, and which allows operation and maintenance without hindrance and also makes possible free access to the print units as well, and assures a secure axial positioning of the printing plate.
This object is attained in accordance with the invention by means of a plate preparation device which is situated near the plate cylinder. A cross arm carries at least one gripper and pressing device and is movable in a transport plane which is generally parallel to a tangent of the plate cylinder. A gripper unit of the gripping and pressing device is equipped with suction strips which act on the printing side of the printing plate. This gripper unit is movable toward and away from a suspension strip of the cylinder and is movable parallel to an axis of rotation of the cylinder along the suspension edge of the cylinder. A printing plate fixed on the gripper unit can be pressed against lateral register stops on the suspension strip of the cylinder.
In a particularly advantageous manner, an exact axial positioning of a printing plate on a cylinder parallel with the axis of rotation of the cylinder against lateral register stops takes place by means of a defined force, for example by a force generated by prestressed springs, or by pneumatic cylinders. Thus no sensor and drive regulation are necessary. Furthermore, the position of the printing plate on the cylinder is independent of the exactness of the feed devices and therefore is extremely exact.
In an advantageous manner, the beveled suspension edges of the printing plate can have legs with an opening angle alpha of less than 90°, because of which it is possible to employ symmetrically designed closures with pivotable clamping flaps. These closures allow running of the machine both in the right and the left running direction of the cylinder.
By means of the tangential arrangement of a preparation device in respect to the cylinder, in an advantageous manner a gripper and pressing device only performs a linear movement for transporting the printing plate from the preparation device to the cylinder.
An inking unit protector is embodied as the preparation device in a space-saving manner, and the gripper and pressing device remains in a parked position in the printing unit in the vicinity of the cylinder, where it is protected against dirt and ink spatters.
BRIEF DESCRIPTION OF THE DRAWINGS
The device in accordance with the present invention is represented in the drawings and will be described in more detail in what follows.
Shown are in:
FIG. 1, a schematic representation of the device in accordance with the present invention in a top view,
FIG. 2, a schematic representation of a gripper and pressing device of the device in accordance with the present invention in FIG. 1,
FIGS. 3 to 11, schematic lateral views of the device in accordance with the present invention with associated cylinder and preparation devices in various operating positions, and
FIG. 12, a schematic section through a closure of the cylinder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cylinder 1 of a rotary printing press with easily bendable curved objects 2, preferably printing plates 2.
Respectively beveled front and rear suspension edges 3, 4 are disposed on opposite ends of every easily bendable curved object 2 as may be seen in FIG. 4 and, whose respective legs 6, 7 form an opening angle alpha of less than 90°. These beveled suspension edges 3, 4 are embodied to be dimensionally stable, i.e. these beveled suspension edges 3, 4 are not bent open when clamping the objects 2 on the cylinder 1. This object 2 designed in this manner can also consist of rubber blankets provided with beveled suspension edges 3, 4.
These dimensionally stable beveled suspension edges 3, 4 of the rubber blankets can be beveled edges of a metal plate, on which the rubber blanket is fastened by adhesion between the materials, for example glued or vulcanized. It is also possible for particularly the textile inserts of the rubber blanket to be made of CFK (carbon fiber reinforced plastic) or GFK (glass-fiber reinforced plastic) and the beveled suspension edges 3, 4 to be formed from this. For simplification, the described object is hereinafter called printing plate 2.
An inking unit protector 11, which is located close to the cylinder, as seen in FIG. 3, fixed in the frame, and which is embodied as a first printing plate preparation device 12, is associated with the cylinder 1 of the rotary printing press, which is seated in two side frames 8, that are shown in FIG. 1 9.
This printing plate preparation device 12 has an upper wall 13 and a lower wall 14, located opposite the upper, which together form a chute 16. A suspension strip 19 of nose-shaped cross section, which extends over the width of the cylinder 1 and extends parallel with an axis of rotation 18 of the cylinder 1, is disposed at an end 17, close to the plate cylinder, of the upper wall 13 of the printing plate perparation device 12. The end 17, close to the plate cylinder, of the upper wall 13 is designed approximately parallel with a tangent 21, which is determined by a cylinder surface 22 of the cylinder 1 and the suspension strip 19 of the printing plate preparation device 12.
It is possible, as in the instant example, for a second printing plate preparation device 23 to be disposed besides the first printing plate preparation device 12, whose end 24 close to the plate cylinder is also provided with a suspension strip 26 of nose-shaped cross section and which is embodied approximately parallel with the tangent 21 determined by the cylinder surface 22 of the cylinder 1 and the suspension strip 19 of the first printing plate preparation device 12.
Respectively a right and left linear drive 27, 28 as depicted in FIG. 3, is fastened in the side frames 8, 9 above and parallel with this tangent 21, which for example respectively consists of thread spindles 29, 31, which are rotatably seated in brackets 32, 33, 34, 36 fixed on the frame. It is possible to employ other known linear drives 27, 28, for example belt or chain drives, toothed rack drives, hydraulic or pneumatic servo cylinders or linear motors, in the same manner. A synchronous rotating movement of the threaded spindles 29, 31 is generated by means of a belt 37, for example a toothed belt, which mechanically synchronizes the right and left threaded spindles 29, 31. This synchronization can take place mechanically also by means of chain or drive shafts or electronically via two separate drives 38 of the linear drives 27, 28. The two threaded spindles 29, 31 move a cross arm 39, seen in FIGS. 1 and 2, and which is parallel with the axis of rotation 18 of the cylinder 1, in a transport plane 41 which is located above and approximately parallel with the tangent 21 determined by the cylinder surface 22 of the cylinder 1 and the suspension strip 19 of the printing plate preparation device 12. Threaded nuts 42 are respectively disposed at the two ends of this cross arm 39, so that the cross arm 39 is in an operative connection at right angles with the threaded spindles 29, 31. At least one gripper and pressing device 43 is fastened along this cross arm 39, in the represented example shown in FIG.1 there are provided four gripper and pressing devices 43.
An independently operable gripper and pressing device 43 is associated with each individual printing plate 2 associated with an axial cylinder section. However, in the same way it is also possible by means of an additional linear drive, through which a single gripper and pressing device 43 performs an axial movement along the cross arm 39, to change several printing plates 2 disposed along the cylinder 1 with only a single gripper and pressing device 43.
The elements of a gripper and pressing device 43 are represented in FIG. 2:
A gripper and pressing device 43 consists of at least one gripper unit 44 and at least one pressing roller 46. This gripper unit 44 and the pressing rollers 46 are individually displaceable by means of positioning devices independently of each other in respect to the cylinder 1 in the radial direction "D", and the gripper unit 44 additionally also in the axial direction "C".
In the instant example, the gripper and pressing device 43 is constructed approximately symmetrical in respect to the center line of the printing plate 2 extending in the direction of the cylinder circumference:
In each gripper and pressing device 43, a gripper unit 44 is embodied, for example, in the form of two suction strips 47, which are displaceable, secure against relative twisting, perpendicularly in respect to a guide strip 48 opposite the tangential direction "B" of the cylinder 1, and are pushed in the direction "B" against a stop 51 by pressure springs 49.
These guide strips 48 are fastened on a further guide strip 52 and are displaceable opposite the direction "C" by means of a pneumatic cylinder 53. A pneumatic cylinder 54 causes a position change of the guide strip 52 with the suction strips 47 along the direction "D". A pressing roller 46 is respectively located next to the suction strips 47, which can be placed against the printing plate 2 opposite the direction "D" via a pneumatic cylinder 56.
In the instant example, as seen in FIG. 3, four closures 57, 58, 59, 61 are disposed in the cylinder 1 in the axial direction, extending parallel with the axis of rotation 18 of the cylinder 1. The length of the closures 57, 58, 59, 61 respectively is approximately half a cylinder length. These closures 57, 58, 59, 61 are again divided in the width of the plate (i.e. respectively two printing plates 2 are provided per closure 57, 58, 59, 60), and can be independently actuated both within this division and also in respect to each other. The closures 57, 58 are offset in respect to each other by approximately 90° in the circumferential direction of the cylinder 1. A closure 59, 61 is respectively associated with each opposite closure 57, 58.
The mode of functioning of the closures 57, 58, 59, 61 will be explained in more detail below by reference to the closure 57 which is depicted in detail in FIG. 12.
The closure 57 is disposed in a cylinder hole or channel 62 extending parallel with the axis of rotation 18. Respectively one front and one rear suspension strip 63, 64 of a nose-shaped cross section is disposed on the cylinder 1 and delimits the cylinder hole or channel 62 beneath the cylinder surface 22. The closure 57 has a right and a left clamping flap 66, 67. Each one of these clamping flaps 66, 67 extends approximately over the width of the plate in the axial direction along the axis of rotation 18 of the cylinder 1. The cross section of both clamping flaps 66, 67 is embodied circular arc-shaped on its lower end as a seating place, from which a lever 69 projects, which terminates in a hook-shaped nose 71. In the opened state of the clamping flaps 66, 67, their noses 71 are located below the cylinder surface 22, and their sides 72 facing the suspension strips 63, 64 of the cylinder 1 are beveled in correspondence with the suspension strips 63, 64 of the cylinder 1, so that in the opened state the clamping flaps 66, 67 are essentially covered by the suspension strips 63, 64.
In the clamped state of the clamping strip 67, a side 73 of the nose 71 of the clamping flap 66 facing the beveled suspension edge 4 of the pressure plate 2 extends approximately parallel with the beveled suspension edge 3 of the printing plate 2. The circular arc-shaped end 68 is respectively seated pivotably in a circular arc-shaped recess 74 of the cylinder hole or channel 62, which extends parallel with the axis of rotation 18. Under the action of springs, the clamping flap 67 performs a pivot movement in the direction towards the rear beveled suspension edge 4 of the printing plate 2 which is to be clamped. In the instant example, the circular arc-shaped end 68 of the clamping flap 67 is provided with a bore 77, through which a rod-shaped torsion spring (torsion bar) 76 extends. On one of its ends, this torsion bar 76 is rigidly connected with the cylinder 1, while its second end is fixed in place on one end of the clamping flap 67.
It is possible, as in the described example, for a further clamping flap 66 to be disposed axially symmetrical in respect to a center line 78 opposite this clamping flap 67 (so that it is also possible to operate in the opposite direction of rotation of the cylinder 1), or only a filler could be inserted. A device generating a force acting on the lever 69 of the two clamping flaps 66, 67 is disposed between these two clamping flaps 66, 67 or the filler. In the instant example, a non-elastic, inflatable hose 79 is disposed between the two clamping flaps.
With the clamping flaps 66, 67 closed, i.e. with a clamped printing plate 2, this hose 79 is compressed flat between the clamping flaps 66, 67. If this hose 79 is charged, for example with compressed air, by means of the change of the shape of the hose 79 it generates a force acting opposite the torsion bar 76 on the lever 69 of the clamping flaps 66, 67 and they therefore pivot in the direction of the insertion strips 63, 64 of the cylinder 1, because of which the closure 57 opens and the beveled insertion edge 4 of the printing plate 2 comes free.
The changing process of a printing plate 2 will be explained in more detail by reference to means of FIG. 2 to FIG. 11:
The cross arm 39 with the gripper and pressing device 43 is moved from a parked position into its unclamping position by the two linear drives 27, 28, while the cylinder 1 rotates into its unclamping position. The unclamping position of the cross arm 39 is determined in that the cross arm 39 is located approximately on or close to a perpendicular line 81, drawn from the axis of rotation 18 of the cylinder 1 to the threaded spindles 29, 31 of the linear units 27, 28. Thus, in this unclamping position the pressing rollers 46, which later are placed against the printing plate 2, determine a loosening point 82 of the printing plate from the cylinder 1 in such a way that a tangent 83 applied in the loosening point 82, i.e. the printing plate 2, as seen in FIG. 4 terminates in the chute 16 of the printing plate preparation device 12. The unclamping position of the cylinder 1 as seen FIG. 3 is determined in that the described perpendicular line 81 forms an angle of approximately 10° opposite the production direction with a connection line formed by a center line 78 of the closure 57 and the axis of rotation 18. The parked position of the cross arm 39 with the gripper and pressing device 43 is located in the transport plane 41, viewed in the plate feed direction A, at least sufficiently far behind the perpendicular line 81 extending from the axis of rotation 18 of the cylinder 1 to the threaded spindles 29, 31, that manual printing plate changes, for example, can be performed, for example 100 mm to 200 mm. Thus the parked position is located outside of the plate transport path. The two pressing rollers 46 are pressed on the loosening point 82 of the printing plate 2 by the pneumatic cylinders 46 in order to prevent slippage of the printing plate 2 on the cylinder 1 as seen in FIG. 4. Thereafter a closure 57 of the cylinder 1 opens and the cylinder starts to turn opposite the production direction "P"(FIG. 3). Because of the inherent stiffness of the printing plate 2, it springs out of the closure 57 which, following a rotating movement of the cylinder 1 of approximately 10°, closes again.
During the rotating movement of the cylinder 1, the printing plate 2 is guided on the cylinder 1 in a frictionally connected manner because of the force effect of the pressing rollers 46, and in this way the printing plate end reaches the chute 16 of the inking unit protector 11. The cylinder 1 stops as seen in FIG. 4 approximately 10° to 30° before the front suspension strip 63 of the cylinder 1 reaches the pressing rollers 46, and the printing plate 2 is fixed in place in the chute 16 by means of a not further shown device. Thereafter, the cylinder 1 turns at least far enough against the production direction "P", because of which the printing plate 2 is displaced on the cylinder 1, until the printing plate 2 springs out of the suspension strip 63 because of its inherent torsion as shown in FIG. 5. The pressing rollers 46 are drawn back from the cylinder 1 by means of the pneumatic cylinders 56.
The printing plate is subsequently removed from the cylinder 1 by means of a device, not shown, in the chute 16 and is completely transported into the chute 16.
For clamping a fresh printing plate 84, as seen in FIG. 6 the cylinder 1 turns into its initial position which is determined in that the center line 78 of the closure 57 is approximately congruent with the perpendicular line 81 extending perpendicularly with the movement direction of the linear drives 27, 28 from the axis of rotation 18. The cross arm 39 is brought into a position for receiving the fresh printing plate 84 by means of the two linear drives 27, 28, i.e. the suction strips 47 are located in the area of the end close to the plate cylinder of the printing plate preparation device 12. The gripper unit 44 is displaced opposite the direction "C" by charging the pneumatic cylinder 53 with air.
The printing plate 84 to be newly applied had been placed pre-positioned on the upper wall 13 and on the suspension strip 19 of the printing plate preparation device 12.
The suction strips 47 are lowered to the level of the printing plate 84 by bleeding the air from the pneumatic cylinders 54 and are charged with suction air, as seen in FIG. 6. By means of this, the printing plate 84 is fixed with its printing side on the gripper and pressing device 43. The cross arm 39 is now moved in the direction toward the cylinder 1 and after a distance of approximately 10 mm has been traveled, the suction strips 47 with the printing plate 84 are lifted by means of the pneumatic cylinders 54.
The cross arm 39 with the gripper and pressing device 43 conveys the printing plate 2 in the direction toward the front suspension strip 63 of the cylinder 1 until the front beveled suspension edge 3 of the printing plate 84 forms a gap "s" with the suspension strip 63 of the cylinder 1, so that the gripper unit 44 with the suction strips 47 can lower the printing plate 84 by means of the pneumatic cylinder 54 on the cylinder surface 22 as seen in FIG.7. This gap "s" is approximately 2 mm to 5 mm.
Following the lowering of the printing plate 84, the linear drives 27, 28 move the gripper and pressing device 43 opposite the direction "A" until the front beveled suspension edge 3 of the printing plate 84 rests exactly against the suspension strip 63 of the cylinder 1 and the suction strips 47 pre-stress the printing plate 84 with a defined force opposite the direction "B". This is shown in FIG. 8.
Subsequently the printing plate 84, which is held by the suction strips 47, is positioned axially and parallel with an axis of rotation 18 of the cylinder 1 on a respective lateral register stop 86 which is shown in FIG. 12 with a defined force, for example resiliently, by actuating the pneumatic cylinder 53, so that the printing plate 84 rests securely against the lateral register stop 86, but is not deformed. The spring force for positioning the printing plate 84 can be generated, for example, by means of the spring of a single-acting pneumatic cylinder 53 or by the air pressure (for example adjustable by means of pressure regulators) of a double-acting pneumatic cylinder. The lateral register stops 86 are fixed with the cylinder on the suspension strip 63 of the cylinder 1 below the cylinder face 22. In the example shown, a common lateral register stop 86 is located on the left or right lateral edge of the printing plate 84 associated with the respective cylinder section.
The described functioning of the pneumatic cylinder 53 applies in case of the disposition of the lateral register stop 86 on on the left lateral edge, i.e. in the direction C. In case of the disposition of the lateral register stop 86 on the right lateral edge, the pneumatic cylinder 53 must act in the opposite direction.
Afterwards, the two pressing rollers 46 are lowered by means of the respective pneumatic cylinders 56 on the printing plate 84. The suction air of the suction strips 47 is shut off and the suction strips 47 are lifted in the direction "D" by charging the pneumatic cylinder 54 with suction air, as may be seen in FIG. 9.
Thereupon the cylinder 1 turns in the production direction "p" until the pressing rollers 46 are located approximately 10° to 20° ahead of the rear beveled suspension edge 4 of the printing plate 84, whereupon the closure 57 opens, as shown in FIG. 10. Subsequently, the cylinder 1 turns approximately 5° to 10° in the production direction "P" and the printing plate 84 is clamped on the cylinder 1 by closing the closure 57. The pressing rollers 46 are raised and the cross arm 39 with the gripper and pressing device 43 moves into the parked position. There the pneumatic cylinder 54 is bled and the gripper unit 44 is lowered, as depicted in FIG. 11. In this parked position, the gripper and pressing device 43 is surrounded by a protector 87 which is closed on at least three sides and is protected there against dirt and ink.
Alternatively, it is possible to perform a further plate change in the described manner. For this purpose, the second printing plate preparation device 23 is disposed next to the first printing plate preparation device 12, so that the end 24, close to the cylinder, of the printing plate preparation device 23 is also embodied for positioning a second, fresh printing plate 88 approximately parallel with the tangent 21 of the cylinder surface 22.
Corresponding to the first described removal process, the chute 16 of the first preparation device 12 receives a second, used printing plate 2.
For mounting the second, fresh printing plate 88 it is placed pre-positioned on the second preparation device 23, and the mounting process takes place in a manner equivalent to the first one. | A device for mounting, removing and transporting an easily bendable device, such as a printing plate, to and from a plate cylinder includes a printing plate preparation device which supports the plate, and a cross arm with a plate gripper and pressing assembly. A gripper portion of the plate gripper and pressing assembly acts on the plate and is movable toward and away from a suspension strip of a cylinder. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is in the field of location based communication, specifically as relating to geotagged asynchronous threaded conversations between multiple participants.
2. Description of the Related Art
With the advent of global positioning satellites (GPS) and smart cellular phones, exemplified by the popular iPhone and Android devices, various methods of geotagging data have become popular.
For example, Phillips et. al., in U.S. Pat. No. 7,848,765, taught a location based social network service in which users could define a geofence, pass the current location of a portable electronic device to an application server, and transmit instructions to the user to offer a service that is not offered when the user is outside of the geofence.
By contrast, Oh, in U.S. patent application 2010/0056183, taught a method and system for providing location based communication services in which access to a real time chat session between a user and a defined group of other users based on detecting when the user was within a certain proximity of a point of interest, and establishing electronic communication between the user and the group of users.
Birnie and Fortescue, in U.S. patent application 2008/0104227 taught a searching and route mapping method based on a social network, location, and time. Here GPS methods of contacting other social network members based on the location of the other social network members were taught. By contrast, Fortescue and Birnie, in U.S. Pat. No. 7,917,152 taught using GPS methods to allow social network members to request the positions of other social network members.
Yardeni et. al., in U.S. patent application 2007/0271367, also taught a system and method for location-based social web interaction and instant messaging. The system allows the various locations of instant messaging users to be plotted on a map.
In spite of these advances, and in spite of the popularity of smart phones and other devices equipped with various types of location determining means, including location by triangulation between different cell phone towers, and GPS methods, geotagged based communication methods are still not widely used. Thus further advances in the field would be desirable.
BRIEF SUMMARY OF THE INVENTION
The invention is based, in part, on the insight that there is an unmet need for what might essentially be described as an improved electronic version of a physical bulletin board. That is, there is a need for a location based electronic messaging system where casual users or strangers can post location based electronic messages in a public or semi-public forum, and receive answers from other strangers. However unlike a real bulletin board, in the invention, users are posting geotagged message threads—that is essentially a framework for an exchange of messages on a topic. Further, users may post these geotagged message threads from a distance, and read these geotagged message threads from a distance, yet require local proximity in order to join the message thread and respond to the message thread.
There are many situations in life where individuals wish to communicate with strangers, but not necessarily or even desirably in on an instant or synchronous basis. These can range from “lost dog” signs that might be posted on a neighborhood telephone pole, advertisements to sell or give away furniture that might be posted outside of an apartment house, questions about how to get access to a particular local service, local advertisements, and the like. Often individuals wish to remain anonymous for these types of postings, and often answers from other local strangers, who may otherwise be connected in any way with the poster's social network, may not come for hours, days, weeks or even longer. Such messages are asynchronous messages, because the different parties communicating do not have to be “online” or even awake or in the same location at the same time.
In contrast to isolated messages that do not require or provide a means for specifically responding to that message, messages that create a framework in which other users can then join in a reply and begin an asynchronous dialog are often referred to as “threaded” messages, because both sides (e.g. the original message, and some or all of the follow-on messages) are considered to form a continuous “thread”. Often this thread presents the various communications in chronological order, with the earliest entry first. Often also multiple entries may be displayed on the same screen. The invention contemplates the desirability of geotagging such message threads, and creating certain location based rules for viewing and responding to the thread.
More specifically, the invention is also based, in part, on the insight that although prior art physical bulletin boards, post-it-notes, messages tacked to telephone poles fill a useful purpose, they have some limitations, which do not necessarily have to be transferred to a electronic bulletin board. For example, although it is impractical for a person based in New York to view a physical bulletin board that is based in Paris, such functionality might be useful. Thus for example, someone from New York intending to go to Paris, and wishing to purchase used furniture or other small item not normally advertised online, might desire to view the local Paris bulletin boards for useful items. Even better, a person based in New York might wish to advertise his or her desire to, for example, locate an apartment in a particular neighborhood in Paris, and might wish to place a local posting in advance of actually traveling to Paris. Here the poster of this thread is only interested in responses from informed sources, such as residents of a particular Paris neighborhood. Thus the poster of the thread may further create the thread with the condition that to reply, the person replying must be within a certain close geographical proximity to the Paris geolocation of the thread.
This invention is based, in part, on a recognition that it is desirable to place geographical restrictions on the asynchronous and threaded communications between strangers in certain situations, but these restrictions do not need to be uniformly symmetrical. In particular it may be desirable to place more geographical restrictions on replying to a thread than the geographical restrictions on creating a thread and viewing a thread.
Thus in one embodiment, the invention may be a communication by location method. The method will typically work with a mobile computerized device, often a smart phone or wireless tablet, which will typically be equipped with at least one computer processor (microprocessor), memory, user interface, display screen, bidirectional wireless communication link capability, and location determination capability such as a GPS receiver, or at least an ability to have its location triangulated using various cell phone towers, Wi-Fi router identification, or alternate method.
In operation, the invention will create at least one communication thread, typically an asynchronous communication thread, on a database associated with a host internet server or other type application server. Each of these communication threads will typically comprise at least an initial entry (e.g. a heading such as “lost dog”), and at least one set of geographical identification metadata that has at least the communication thread geolocation (i.e. the location where the user wishes to post the message), a communication thread category (e.g. event, housing, marketplace, miscellaneous, place, question, service thought, work, etc.), a first communication thread viewing geographical zone (i.e. how far away from the thread geolocation can the message thread be seen), and a second communication thread reply geographical zone (i.e. how close do you have to physically be to the location of the message to post a reply). This second reply geographical zone will encompasses at least the geolocation of that communication thread, and this second reply geographical zone will be encompassed within the first viewing geographical zone.
Although these various zones do not have to be circular, in the embodiments where they are circular, the net effect is not unlike a bull's eye, where the center of the bull's eye is the thread location, the first ring is the reply zone, and the largest ring is the viewing zone. Usually the diameter of rings (or to generalize, the shape and size of the zone) will be user adjustable by the creator of the thread, who usually will also post the first message. Note that the geographical location of the original thread posting does not necessarily have to be at the thread creator's user's present location, although it may be. Rather, a thread creator may decide to geolocate (i.e. “pin”) a thread to a remote location. In some embodiments, the thread creator will be given a unique privilege, not available to other thread users, of being able to view and post to his or her thread from any location.
To see the message, a second user will use the invention, often in the form of application software (e.g. an “app) running on a suitable computerized mobile device. The second user will often set a map viewing location on his or her mobile device, where this map viewing location may either correspond to the second user's actual physical location, or alternatively may be the user's virtual location that corresponds to the location where the user believes communication threads of interest may be located. The second user may further set a maximum communication thread viewing radius or zone about this map viewing location.
Although this maximum communication thread viewing radius or zone will not enable users (other than the thread creator, who may have a distant viewing privilege) to see threads that have first communication thread viewing geographical zones that too far away from the user's present physical location, the user map viewing location and maximum communication thread viewing radius or zone about this map viewing location act to further filter the results so that the user and the system is not having to handle too many threads from areas that are not of interest to the user.
Thus for example, as per our previous example, a New York located user, after creating a message thread “pinned” or geolocated on Paris asking local Paris residents about local items of interest, may then virtually return (i.e. move his or her map location to Paris), and view this Paris geolocated thread for responses from locals. To do this, the user may set the viewing radius (e.g. the first communication thread viewing zone) of the thread to be quite large, even thousands of miles, but the user will set the reply radius (e.g. the second communication thread reply geographical zone) of the Paris thread to a very small local radius, so that only local Paris users may post replies.
The user (by way of the invention's software application running on the user's mobile device, and the invention's host server software) can then use the mobile device to establish a communications link with the host internet server, transmit the user's present location and map viewing location of his or her mobile device to the host internet server, and also transmit at least a maximum communication thread viewing radius and one or more communication thread categories (e.g. a request to show the user some or all of the various event, housing, marketplace, and so on categories) to the host internet server.
The host internet server can then use the present location and map viewing location of the mobile device, communication thread categories, and maximum communication thread viewing radius as a search key to a thread database, and search for communication threads with communication thread geolocations, communication thread categories, and communication thread viewing zones that are also within the maximum viewing radius of the map viewing location of the mobile device. These results can be used at least as a first search criteria to determine if at least the selected communication thread geolocations of the search selected communication threads should be transmitted to the user's mobile device, and if so, transmit these selected thread geolocations. In other words, if each relevant thread can be considered to be a pin on a map, this step essentially transmits the location of the various selected “pins” to the user.
Users may then obtain further information about the various geolocated threads, titles subject matter, contents and the like, view them on maps and lists, view the various postings, and respond to the various postings as appropriate.
The invention was originally submitted to the Apple App store on Dec. 10, 2010, and was subsequently made available to the public (published) on the Apple App store on Dec. 17, 2010.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 gives an overview of how various communication threads with different geolocations, viewing zones and reply zones may differentially seen and utilized by various users depending upon the geolocations and the maximum communication thread viewing radius of the various user mobile devices. Here the various map viewing locations correspond to the actual physical locations of the various users.
FIG. 2 shows an outline of how the major components of the system interact.
FIG. 3 shows an example of a map viewing location that is displaced from the actual physical location of the user.
FIG. 4 gives an example of message flow between users in New York, London, a Paris suburb, and downtown Paris.
FIG. 5 gives an example of some of the host data flow steps.
FIG. 6 shows some of the steps involved in using a device to post a new single location message.
FIG. 7 shows some of the steps in hosting a new multi-location message.
FIG. 8 shows some of the steps involved in viewing variable message detail on a device.
FIG. 9 gives an example of the data structure of a message thread.
FIG. 10 shows some of the AskLocal settings
FIG. 11 shows a long range (approximately 13.9 mile radius) view of a community showing locations of recent AskLocal users. The present user has used the set location circle to center the display in the user's current location in Los Gatos.
FIG. 12 shows the location of the various long distance thread posts that can be seen from the user's present location in Los Gatos.
FIG. 13 shows a list of some of the various thread posts that can be seen from the user's present location in Los Gatos when the radius is reduced to 11.4 miles.
FIG. 14 shows more detail from the Hacker Dojo thread posting of interest.
FIG. 15 shows a list of some of the various thread posts that can be seen from the user's present location in Los Gatos when the radius is further reduced to 8.2 miles. The Hacker Dojo thread post of interest has disappeared because it is more than 8.2 miles away.
FIG. 16 shows what happens when the user drives closer to the point of interest, and the message reception radius is further reduced to 3.8 miles. By pressing on the various thread post pins, the user can find out more about the thread posts. Here one thread post is from a Photography service.
FIG. 17 shows that another post is for the Hacker Dojo thread post and location of interest.
FIG. 18 shows the lists of thread posts from the user's present location, showing the various posts that can be seen within a 3.8 mile radius.
In FIG. 19 , the user has almost reached the Hacker Dojo thread post of interest.
In FIG. 20 , the user replies to the Hacker Dojo thread by replying with a question for the local Hacker Dojo members, here asking for the Wi-Fi access code so that he can get wireless access once he reaches the Hacker Dojo location. This reply is only visible from within the context of the main Hacker Dojo post. It is otherwise not independently visible.
In FIG. 21 , the result of the user's question is shown as a new entry on the original Hacker Dojo thread post seen previously.
In FIG. 22 , the user has essentially at the front door of the Hacker Dojo thread post and location. Thus when the user reduces the message radius to only 62 feet, the Hacker Dojo thread post can still be seen.
In FIG. 23 , the user wishes to create a new thread in the question category. The user wishes this thread to be seen fairly broadly throughout the user's present Silicon Valley location, including the Apple Corporation Headquarters located within about 10 miles of the thread geolocation, but which can only be replied to by individuals who are near the location of the Hacker Dojo building and original Hacker Dojo thread post.
FIG. 24 shows the user's new question thread showing up on a map right next to the Hacker Dojo entrance. Here the user has also switched from map view to satellite, view, which is shown in high enough magnification that the Hacker Dojo building, parking lot, street, cars, and trees can clearly be seen. The user's new thread post now shows up in a location that is geographically very close to the original Hacker Dojo thread post.
FIG. 25 shows the user's new thread post showing up on the map.
FIG. 26 shows a map view of the same location, again showing the new user thread post.
FIG. 27 shows what the user's new thread post looks like to other AskLocal users.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 gives an overview of how various communication threads with different geolocations, viewing zones and reply zones may be differentially seen and utilized by various users depending upon the geolocations and the maximum communication thread viewing radius of the various user mobile devices. As previously discussed, these mobile devices will generally be smart phones, tablets, laptop computers, and the like, exemplified by the popular iPhone and Android devices, that will typically be equipped with at least one processor, memory, user interface, display screen, bidirectional wireless communication link capability, and location determination capability.
This example shows various mobile device equipped users interacting with various geolocated communication threads within a geographical area ( 100 ). This geographical area is of arbitrary size, and may be as large as all of planet earth, or be as small as various locations within a single building, but in any event the position of the various objects within the geographical area ( 100 ) is intended to represent their relative geographic positioning in terms of, for example, latitude and longitude. In FIG. 1 , assume that all users have set their map viewing location to correspond to their present actual location. The case where a user's map viewing location is different from a user's present actual location will be discussed subsequently in FIG. 3 .
In this example, user 1 ( 102 ) has posted two different asynchronous communication threads to two different geolocations ( 104 ) and ( 106 ). Note that according to the invention, the user does not have to be physically present in a particular location in order to geolocate a thread to that location.
The geolocation of each asynchronous communication thread (which will often be abbreviated here as “communication thread” or even simply “thread”) is represented by a symbol of a push pin, where the base of the pin represents the precise geolocation of the thread, and the head of the pin is provided in order to make the pin more conspicuous and/or also help distinguish between different threads (e.g. using different colors, different shapes, and so on).
Note that in this example, the two threads ( 104 ), ( 106 ) created by user ( 102 ) may represent totally different subjects and, except for the fact that they were created by the same user operating from the same real geographical location ( 102 ) may otherwise have nothing in common with each other. In an alternative embodiment, the system can be configured so that the same user can send the same message to multiple locations at the same time. This later option can be useful when, for example, there is a need to send the same message to multiple related sites. Thus a chain store worker, for example, can pin the same type of message to multiple chain store locations. Keep in mind however, that as a general rule, the vast majority of the various threads are expected to be posted on a non-duplicated basis.
Each thread will typically comprise or contain at least an initial entry (usually the thread originator's or owner's first post), geographical identification metadata such as the communication thread geolocation, a communication thread category, a first communication thread viewing geographical zone, and a second communication thread reply geographical zone. Some of the categories that a communication thread may be assigned to include categories such as event, housing, marketplace, miscellaneous, place, question, service, thought, work or other categories.
In some embodiments of the invention, the thread owner or originator may also specify additional properties of the thread. Here some of these choices may include: 1: only the original poster can view all replies regardless of his or her physical location, 2: in addition to the original poster, people located within the reply distance can see replies, or 3: additionally, people located within the viewing distance may also see replies. In principle all permutations are possible; however certain preferred options will be discussed in more detail.
Thus, for example, when the user 1 set up thread ( 104 ), the user established a first viewing geographical zone ( 108 ) and a second reply geographical zone ( 110 ). Similarly when the user 1 set up thread ( 106 ), the user established a first viewing geographical zone ( 112 ) and a second reply geographical zone ( 114 ) for that thread as well. The various zone sizes can be different for each thread, however the second reply geographical zone (e.g. 110 , 114 ) encompasses at least the geolocation of the communication thread (e.g. 104 , 106 ), and the second reply geographical zone (e.g. 110 , 114 ) is encompassed within the first viewing geographical zone (e.g. 108 , 112 ). Although the zones are drawn here as circular zones with a radius centered at the geographic location of the thread(s) ( 104 ), ( 106 ), in fact the zones can be other shapes, such as regular polygons or even irregular shapes, as long as the basic rule: thread geolocation is inside of the reply zone, which is inside of the viewing zone, is maintained.
Once posted, various other users 2, 3, 4, and 5 can use their devices to attempt to view or interact with the various threads. Here for example, user 2 ( 116 ) who has set a maximum communication thread viewing radius ( 118 ) on his device as shown, will be able see or detect communication thread ( 104 ), because user 2 is both physically located within the viewing zone of ( 108 ) of communication thread ( 104 ), (or at least right on the boundary of viewing zone ( 108 )), and is also informed the system, by setting his or her virtual map location to this region, that he is interested in receiving ( FIG. 3 and associated discussion). However user 2 is not close enough to communication thread ( 104 ) to make a reply to communication thread ( 104 ) because user 2 is physically located outside of reply zone ( 110 ), and the creator of the posts (user 1) has set the criteria that in order to reply, the user must be physically located (not virtually located) close to the posts. User 2 is also too far away from communication thread ( 106 ) to either view communication thread ( 106 ) or post to it.
By contrast, user 3 ( 120 ), who is outside of the view communication zones of threads ( 104 ) and thread ( 106 ), and who has not created thread ( 104 ) or ( 106 ), cannot see or interact either thread, irrespective of where he sets his virtual location, or how he sets his maximum communication thread viewing radius ( 122 ).
On the other hand, user 4 ( 124 ), who has set a fairly small maximum communication thread viewing radius ( 126 ), is able to see thread ( 106 ) and reply to thread ( 106 ) because user 4 is physically located inside thread ( 106 )'s first communication thread viewing geographical zone ( 112 ), inside of thread ( 106 )'s second communication thread reply geographical zone ( 114 ), and also has specified by user 4's virtual location and how he sets his maximum communication thread viewing radius that he is interested in interacting with threads in this region.
Finally user 5 ( 128 ), who also did not create threads ( 104 ) and ( 106 ), and who has set a very wide maximum communication thread viewing radius ( 130 ), is still unable able to view or post to ether threads ( 104 ) and ( 106 ), even though he has told the host server that he is interested in receiving information about threads from these regions, because user 5 is physically too far away from their viewing zones and reply zones.
As previously discussed, in at least some embodiments of the invention, there may be no geographical posting or reply restrictions on at least the owner or originator of a communication thread. Thus in this example, as previously discussed, user 1 ( 102 ) is able to create communication threads ( 104 ) and ( 106 ) from a considerable distance away, in fact from outside of the first viewing geographical zones ( 108 ), ( 112 ) of either thread. In other embodiments of the invention, however the owner of a post may have certain geographic thread creation restrictions applied. The exact rules will be a determined by a matter of system (e.g. host server) policy and thread creator preferences.
The lack of geographic restrictions on at least the originator of a communications thread has some useful advantages. Thus, for example, an individual planning to travel from New York to Paris may create a local Paris posting while still in New York. However it is anticipated that frequently users will choose to set the geolocation of the communication's thread at their present location at the time of posting.
In order to accomplish this functionality, the system makes use of various types of communications equipment, and servers. FIG. 2 shows an outline of how the major components of the system interact.
Here the various mobile devices ( 200 ), ( 202 ), corresponding to the mobile devices used by users 1-5 in the previous figure, will often establish their geolocation through use of various location determination devices, such as GPS satellites ( 204 ), or alternatively by alternate location determination methods such as cell phone tower triangulation, Wi-Fi router identification, and so on (not shown). The mobile devices will in turn communicate through a network such as the Internet ( 206 ), often by an intermediate cellular wireless connection to various cell phone towers (not shown), or alternatively through local Wi-Fi links to the Internet (not shown).
Using the network ( 206 ), the various mobile devices will generally interact and exchange data relating to the various communication threads by way of host server (host application server, host internet server) ( 208 ). This data will generally be stored and managed on one or more databases ( 210 ) connected to host server ( 208 ). Additionally, although not an essential part of the invention, the system will often find it convenient to obtain supplemental geographical map information (e.g. locations of streets, buildings, optionally overhead photos of the area, and the like) from a map server ( 212 ), which may be a third party map server such as a Google map server or other type map server.
In contrast to FIG. 1 , where the map viewing locations of all the users was set to correspond to the user's present physical location, in normal use, the map viewing location, which again may be viewed as a filter on the various threads that the user wishes to receive, may often be set by the user to be different from the user's present physical location. This can be done simply by, for example, allowing the user to scroll his or her virtual location on a map, using a touch sensitive screen on the user's mobile device.
An example of this virtual location filtering method in action is shown in FIG. 3 . In FIG. 3 , user 6 ( 300 ) has set his or her map viewing location ( 302 ) (the star) and maximum communication thread viewing radius ( 304 ) to a location that is displaced from the present location of user 6 ( 300 ). This displaced map viewing location and maximum communication thread viewing radius ( 302 ), ( 304 ) encompasses the first communication thread viewing geographical zone of communications thread ( 334 ). However the user's viewing location ( 302 ) and maximum communication thread viewing radius ( 304 ) is outside of the first communication thread viewing geographical zone ( 312 ) (and reply zone 314 ) of communications thread ( 336 ).
Thus in this example, user 6 ( 300 ) has set his map viewing location and maximum communication thread viewing radius in such a way as to filter out any data from thread ( 336 ).
To prevent server overload, as well as data congestion on the wireless link, the host server ( 212 ) will often use this filter to determine that it need not send data from thread ( 336 ) to user 6 ( 300 ).
Note that in this example, user 6 ( 300 ) is still too far away from thread ( 334 ) to post a reply, because the user is still outside of the reply geographical zone ( 310 ) for thread 334 .
In other embodiments, the thread privileges may be set up so that the second reply geographical zone ( 110 ) may also be filtered relative to the user's “virtual” map viewing location ( 302 ), rather than the user's actual physical location ( 300 ).
Thus in use, a user of the mobile device will typically set a map viewing location ( 302 ) on his or her mobile device. As previously discussed, this map viewing location will often correspond to the location where communication threads of interest may be located, and often will be set to the user's actual physical location, but this is not required. Thus the map location may be set to a location other than the current location of the user's device. In some embodiments, the device software may provide a means, such as a touch sensitive homing button, to cause the map viewing location ( 302 ) to return to the user's present physical location ( 300 . Often also, the map viewing location upon application software startup will default to the user's present physical location.
The user will further set (or else accept system defaults for) a maximum communication thread viewing radius ( 304 ) about this map viewing location ( 302 ). The user will then use his or her mobile device ( 300 ), ( 200 ) to establish a communications link with the host internet server ( 208 ), and the device and software will transmit the user's present location ( 300 ) and the user's map viewing location ( 302 ) of the user's mobile device to this host server ( 208 ). Typically this communications session will also transmit at least the user's maximum communication thread viewing radius ( 304 ) and one or more communication thread categories to the host internet server ( 208 ).
Once this data has been transmitted to the host server ( 208 ), the host server will use this data, such as the present location ( 300 ) and map viewing location ( 302 ) of the user's mobile device ( 300 ), the user selected communication thread categories, and the user selected maximum communication thread viewing radius ( 304 ) as a search key to search database or data store ( 210 ) to search for communication threads (e.g. 104 , 106 ) with communication thread geolocations, communication thread categories, and communication thread viewing zones (e.g. 108 , 112 ) that are within the maximum viewing radius ( 304 ) of the map viewing location ( 302 ) of the mobile device ( 300 ). In this example, assuming that the categories will match, a search of database ( 210 ) using user ( 300 ) search keys will return thread ( 104 ) but not thread ( 106 ), since thread ( 106 ) is outside of the present viewing zone for device ( 300 ).
The results of this search can be used as at least a first search criterion to determine if at least the selected communication thread geolocations of the search selected communication threads should be transmitted to the mobile device. Assuming that any other search criteria are also met, the results, such as at least the geolocations of the threads matching the various search criteria will be returned from database ( 210 ) by way of host server ( 208 ) and network ( 206 ) to the user device ( 200 ), ( 300 ) as thread data. Often the search will return more than this, such as, for example, the tile of the thread, thread category, a thread icon, and so on.
Once this basic thread data is returned, the user's device can display this thread data in various ways. One way is to graphically show the geolocations of the various threads on a map, annotated with icons or short descriptions or various informative graphical elements as desired. This method is particularly useful for devices with touch sensitive displays, because here a user can merely touch a pin or other icon showing a thread of interest, and find out more about the thread.
Alternatively or additionally, it is also useful to show the thread data as a list of message threads, often sorted by various criteria such as distance from the user's present real location ( 300 ), distance from the user's map viewing location ( 302 ), age of post, or other criteria. A user may then scroll through the list, and pick threads of interest for further viewing. Often both map displays and list displays may be used, and the user may switch back and forth or alternatively see both side by side as desired.
Map Oriented Methods:
For map oriented methods of interacting with the various threads, as before, the user mobile device may often supplement the thread geolocation data by establishing a communication link ( 206 ) with a map server ( 212 ) and downloading map information pertaining to the geographic region of interest. To do this, the mobile device may transmit the map viewing location ( 302 ) of the mobile device, and usually the maximum communication thread viewing radius ( 304 ) or similar geographic extent data to the map server ( 212 ), and receive back from the map server selected map information pertaining to a geographical map within the maximum communication thread viewing radius of the mobile device. Thus for example, again referring to FIG. 3 , user 6 ( 300 ) may end up seeing a map of the area within the dashed line radius ( 304 ) on his or her mobile device. This map will usually show at least portions of the geographical map of the area around dashed line ( 304 ).
Not all map data needs to be displayed by the user's device. Different levels of detail may be chosen, only road map data may be shown, only map image data (i.e. satellite photos of the area) may be shown, and so on. The user's device will often also overlay the map data with icons representing the geolocations of the search selected communication threads. That is, if the database ( 210 ) and host server ( 208 ) returned the geolocation of message thread ( 334 ), often it will be useful to show this on the user's display superimposed on a map of the area. Here icons such as push pins or other icons are useful for showing this, but of course nearly any graphical display method will work here. In a preferred embodiment, the icons or other message showing the location of the message threads, such as ( 334 ) will be made touch-sensitive or clickable so that a user can touch or click on a thread of interest to find out more about it (i.e. make further inquires).
In some embodiments, it will be useful if the host server ( 208 ) additionally transmits additional information, such as the category of the search selected communication threads, headings or titles, icons, and so on. If this is done, then the user's mobile device can show a different graphical image according to the category of the various threads. Here, as previously discussed, methods such as color coded icons, icons resembling their subject matter, and of course text based icons (or just text) may be used.
List Based Methods
As previously discussed, in other embodiments, a list based approach for interacting with the various message threads may be useful. Here, for example, the host server ( 208 ) may additionally transmit the category, title, and/or icon of the search selected communication threads to the mobile device. The mobile device may then display this information on a list view, where for example, the list may contain the search selected communication thread geolocations (e.g. 334 , categories, title and/or icon, as well as the distance between the search selected communication thread geolocations and the map viewing location ( 302 ) of the mobile device.
In addition to just returning headings, icons, titles, and the like, at least upon subsequent inquiries from the mobile device, the system will also transmit a more complete record of the thread, such as the various other replies and data submitted by various users after the thread was established. Here how much of this subsequent thread data (e.g. subsequent replies and data) will often depend on the privileges of the user of the mobile device making the inquiry, as well as available bandwidth and data amount considerations.
In many embodiments, either when the communication thread is initially established, or subsequently (potentially even on a per-post basis), the entries in any given communications thread of interest can be further annotated with viewing privilege criteria. These viewing privilege criteria may vary according to the privileges of the user of that particular mobile device, and these privileges will control what data is transmitted and/or subsequently displayed by that mobile device.
These privileges can, for example, include privileges such as the communications thread owner privilege (often the creator of a particular thread may get higher privileges, in effect becoming the system administrator for that particular thread), public privilege (e.g. privileges of general members of the public who have not posted on the thread before), previous poster privilege (here the owner of a particular post may have privileges at least to edit or delete his or her own post), group privilege (e.g. some groups, such as members of a club or company, may collectively have higher privileges), fee-based privilege (self explanatory), and other privileges.
As previously discussed, in some preferred embodiments of the invention, it is useful to restrict subsequent users from submitting additional posts on the thread by according to the user's actual (physical) geographical location. Here, for example the host internet server ( 208 ) may, along with other data, send the mobile device information pertaining to the reply geographic zone (e.g. of 110 ) of a selected communication thread (such as 104 ) a mobile device. The mobile device software and host server software then may, for example, determine that if the present real (physical) location of said mobile device is within the reply geographic zone ( 110 ) of the selected communication thread ( 104 ). If so the software may allow a new (subsequent) entry to this selected communication thread ( 104 ) to be transmitted from the mobile device to the host internet server ( 208 ), linked or added to the selected communication thread ( 104 ), and stored on the database ( 210 ).
In this scheme, for example, if the system is set up to enforce that a user device must be within real geographic proximity of a reply geographic zone ( 110 ), ( 114 ), then device 4 ( 124 ) from FIG. 1 would have reply privileges to thread ( 106 ), but at least devices 2, 3, and 5 would not have reply privileges to either thread ( 104 ) or ( 106 ). Alternatively if the system is set up to allow the thread originator to view and post from anywhere, then device 1 ( 102 ) in FIG. 1 , belonging to the originator of threads ( 104 ) and ( 106 ), can both view and post to these threads from his or her current location ( 102 ), even though it is far away from either thread.
Although often the posts on a thread (either the original post, or subsequent posts) may be text based, in principle any type of data may be included in a particular post. Thus for example, original or subsequent entries can include text, images, audio, video, URL links, binary program files, and other types of data.
EXAMPLES
FIG. 4 gives an example of a hypothetical message flow between users in New York, downtown Paris, a Paris suburb, and London. Here user 1 ( 400 ) who is located in New York may initiate a thread by first moving his virtual map viewing location to Paris by scrolling on his the map display on his device, or other method. Here, the displayed may be based on map data obtained from the map server ( 212 ) as previously described, while the actual thread message will be posted on the host server ( 208 ).
In this example, as a result of the thread creation event, the system has automatically stored a downtown Paris latitude and longitude of the geolocation of the thread on the server ( 208 ). Here the user has specified that the message may be seen from a viewing radius of 20 kilometers from the downtown Paris location, but only users physically located within 500 meters of the geolocation may reply. As a result, with these settings, a second user ( 402 ) using a device from a downtown Paris location may view and reply to this message thread. However a third user ( 404 ), even though nearby (here a Paris suburb) may read the message thread but may not reply. A fourth user ( 406 ), located in London, cannot view the message or reply to the message.
FIG. 5 gives a high-level overview example of some of the host server data flow steps. Here host server ( 208 ) will generally receive the mobile GPS coordinates (or other location data), determine what messages will be visible to the mobile device using the previously described considerations, and then provide the list of messages.
FIG. 6 shows some of the steps involved in using a device to post a new single location message. Here a user will generally select a message destination location and category, enter in a message title and body, and also select the first communication thread viewing geographical zone (i.e. message visibility distance). The user will also select the second communication thread reply geographical zone (i.e. the message reply distance), select user privileges (i.e. who can see the replies), and optionally if there is additional media such as photos or videos and the like, submit the data to the host server ( 208 ).
FIG. 7 shows an example where a user may wish to post to multiple locations in the same session. Here the first part of the process is much as previously described for FIG. 6 , but additionally the user is now given the option to select a second location, and also set the parameters for this location as well.
FIG. 8 shows the process of viewing a message thread on a device. Here the user's mobile device will send its current location to host server ( 208 ), and receive a list of message threads that are visible at the user's current location and settings, as previously described. If the user is operating his or her mobile device in a mapping mode, then in some embodiments, the device will download map data from a map server ( 212 ) and display the message threads (often using pin icons or equivalent) arranged on the map according to the geolocation of the various threads. If the user is operating his or her mobile device in a list view, then the device will often show a list of the selected message threads, which can be sorted depending on user criteria.
In either event, the user will pick a message thread of interest, either by map location or list selection, often by pressing on a touch sensitive display, or by using an equivalent method such as a mouse click. When this happens, the device may show additional details regarding the message, such as the initial posting and (where the user privileges are adequate) subsequent replies as well. If the user is outside the reply radius (i.e. outside of the second reply geographical zone for that message thread), then the device will disable the reply button (for those systems where the user is not given the ability to reply to that message thread). If the user is within the second reply geographical zone (reply radius), then the reply button will be enabled (along with other reply functionality) and the user will be allowed to append his or her reply to that particular message thread.
FIG. 9 gives an example of the data structure of a message thread, and an example of the type of search algorithm that goes on inside of the host server. In FIG. 9 , assume that a user with mobile device 7 ( 900 ) is physically located at latitude 0°, longitude 0°, but has a virtual map viewing location ( 902 ) that is displaced or set ( 914 ) to latitude 1°, longitude 1°, and the thread of interest ( 904 ) is geolocated at latitude 2°, longitude 2°. Assume that in the host server database ( 210 ), thread ( 904 ) was initially set up by the thread originator, with user ID 12345, to be in the miscellaneous category, to have a viewing radius (e.g. first communication thread viewing zone) of about 2.5 degrees (172 miles), and have a reply radius (e.g. a second communication thread reply zone) of about ⅓ degree (23 miles).
Assume further that the system will require that the user device be within the reply radius to post replies to the thread (tie to physical location yes). Assume further that the original poster gave the thread the heading “Example”, an icon of a “pin”, and that the database will then link to the original post and various subsequent messages on this thread (link, details not shown). The database ( 210 ) for this thread, in the context of other threads, can be seen in ( 906 )
Then when user on device 7 ( 900 ) communicates with the host server ( 208 ) and database ( 210 ), the user's mobile device 7 will transmit the device identifier (7), the physical latitude of the device (0°), the physical longitude of the device)(0°), the virtual map latitude of the device)(1°), and the virtual map longitude of the device)(1°), the thread category desired to view (here Misc.) and the device viewing radius (here about 1 degree or 69 miles). An example of this transmitted mobile device data can also be seen ( 908 ).
The server will receive this data ( 908 ), compare it with the various threads in the database ( 906 ), and will calculate if the device physical latitude and device physical longitude places the device within the 172 mile reply radius of thread 904 (assuming 69 miles per degree of latitude and longitude in this example). It will find that device is close enough to see the post using the physical proximity test. The server may also check the User ID (here 32014) versus the thread creator ID (here 12345), and if creator privileges are present, skip this physical proximity test, but in this case the user is not the creator, so the physical proximity test is in effect. (Note that other types of privileges, such as public privilege, previous poster privilege, group privilege, fee-based privilege, and other privileges may be used to modify or skip the physical proximity test according to the system administrator policies then in effect.)
Next the server will check to see if thread ( 904 ) is also within the filter imposed by the user's map viewing location ( 922 ) and maximum communication thread viewing radius ( 924 ). If it is within these criteria as well, then the host server will report data from thread ( 904 ) to user 7 ( 900 ). Otherwise this thread data will be excluded since user 7 has indicated, through choice of map viewing location and maximum communication thread viewing radius, that he or she is not interested in threads from this location.
In this example, thread ( 904 ) satisfies both criteria. The user is within the first communication thread viewing zone, and thread ( 904 ) is within the user selected map viewing location and maximum map communication thread viewing radius. The host server will send the thread data to the user's device, and the user's device will display this data. However as can be seen, user 7 is not close enough to post to thread ( 904 ) because user 7 is outside of the tread ( 904 ) second communication thread reply zone ( 930 ).
Examples of an implementation of the system in operation.
As previously discussed, an embodiment of the invention, termed the “AskLocal” app was published on the Apple App store on Dec. 17, 2010. As a result, numerous users had a chance to download the application and experiment with it. The following figures show screenshots that were taken on Apr. 9, 2011, in Northern California, using a Verizon iPhone 4 Smartphone, and with the exception of the identified replies and postings, the various message threads represent message threads left by other uses of the system.
FIG. 10 shows some of the AskLocal message thread settings. Here the system has been set with a first communication thread viewing zone of 13.9 miles, using a software slider ( 1000 ).
In FIG. 11 , the AskLocal app software has been set to map view, and has been instructed to return the location of the various local AskLocal users (who have authorized release of this data), regardless of if they have posted message threads or not. This map shows a long range (approximately 13.9 mile radius) view. The present user has used the set location circle to center the display in the user's current location in Los Gatos ( 1100 ).
In FIG. 12 , the AskLocal app software has been instructed to only show the geolocation of the various communication threads within 13.9 miles of the user's location, which is still set to coincide with the user's actual location in Los Gatos. Because the user in Los Gatos has not posted a message in Los Gatos, there is no pin at the user's present location.
To get more insight into the content of the various communication threads, the user next switches the AskLocal software to list view, and also reduces the extent of the first communication thread viewing zone from 13.9 miles down to 11.4 miles, here by adjusting a software slider. Various messages, many advertisements of some sort, along with brief captions and icons can be seen in this list view. Assume here that the user is particularly interested in the Hacker Dojo message thread ( 1300 ), and thus selects the Hacker Dojo message thread for further information.
FIG. 14 shows more detail from the Hacker Dojo posting of interest. Here the person who initiated this communications thread set the view radius to 53.5 miles ( 1400 ), which is why the user, who had set his viewing zone to 11.4 miles, and who is only about 10 or so miles away, can see this post. Note however that the person who initiated the thread set the reply radius to only 1.4 miles ( 1402 ). Thus the present user is too far away to reply to this post. The post contains an invitation to check out the place.
FIG. 15 shows what happens if the user further narrows the first communication thread viewing geographical zone down from 11.4 miles to 8.2 miles. Because the user is more than 8.2 miles away from the Hacker Dojo, the Hacker Dojo post can no longer be seen on the list view.
In this example, the user has decided to check out the Hacker Dojo, and has now driven part way towards this destination. Here the user has driven about 5-6 miles on the roughly 9-10 mile trip towards the Hacker Dojo, and has stopped a few miles away to take a look at the local communication threads again.
This is shown in FIG. 16 . Here the user is closer to the Hacker Dojo point of interest, and has also reduced the first communication thread viewing geographical zone (message reception radius) to 3.8 miles. The system has been designed so that the user may take advantage of the iPhone's touch sensitive screen and get more information about a message thread geolocation of interest by pressing on a post pin corresponding to that particular thread on a map view. Here the user is querying various local message threads, here by pressing on the threads on a touch sensitive display, which brings up the tread title or icon, and the thread title. The post in FIG. 16 shows that this particular thread is from a photography service.
FIG. 17 shows that another post is for the Hacker Dojo post and location of interest.
FIG. 18 shows the lists of posts from the user's present location, showing the various posts that can be seen within a 3.8 mile radius. Note how the Hacker Dojo thread, the photography service thread, and other threads previously seen in the map view are also shown on the list view.
In FIG. 19 , the user has almost reached the Hacker Dojo point of interest. The user may now zoom in very closely to the street where the Hacker Dojo building is. In this Figure, the user has set the AskLocal software to show both the Hacker Dojo post ( 1900 ), and the user's present location ( 1902 ) (even though the user has not yet posted), and thus two pins are shown on the map view. At this point, the user is well within the 1.4 mile reply radius (second reply geographical zone) set by the initiator or owner of the Hacker Dojo message thread.
In FIG. 20 , the user uses the AskLocal software and iPhone to add another entry to the Hacker Dojo thread. In this case, the user, perhaps wanting to get access to a Wi-Fi network, asks posts and advance question requesting access to the local Hacker Dojo Wi-Fi access code, hoping perhaps to get an answer by the time the user actually reaches the Hacker Dojo location.
In FIG. 21 , the result of the user's question is shown as a reply to the original Hacker Dojo post seen previously. Here the true thread nature of the Hacker Dojo thread can be seen. Unlike prior art geotagging methods, here a message thread, capable of adding new messages, has been pinned or geolocated to the Hacker Dojo site. Thus both the original posting ( 2100 ) and the reply ( 2102 ) can be seen, and other users may also reply to this posting on this thread as well.
In FIG. 22 , the user has essentially at the front door of the Hacker Dojo post and location. Thus when the user reduces the message radius (e.g. the first communication thread viewing geographical zone) to only 62 feet, the Hacker Dojo post can still be seen.
In FIG. 23 , to demonstrate the process needed to create an entirely new communication's thread, the user decides so create a post with a first communication thread viewing geographical zone with a radius of 25.8 miles ( 2300 ) from the Hacker's current location, which is a few feet away from the entrance to the Hacker Dojo. Here the user, knowing that Apple Corporation Headquarters is only a few miles away, creates a new communication thread where members of Hacker Dojo, or at least people posting near Hacker Dojo, can urge Apple to create an iPhone Software Development Kit (SDK) that would run on the poplar windows operating system. To restrict the reply zone, the user has set the second communication thread reply geographical zone (reply zone) to a radius of about half a mile (2246 feet) ( 2302 ) from his present Hacker Dojo location.
In FIG. 24 , the result of this posting can be seen. Where before there was only one communication thread pin ( 2400 ) outside of Hacker Dojo, now there are two ( 2400 ), ( 2402 ). In this Figure, the user has used the AskLocal software to switch to a photographic map display. As a result, the user's mobile device now shows a highly magnified satellite photograph of the roof of the Hacker Dojo, a nearby parking lot, the road (with a visible “Yield” sign, trees, and two pins that represent the geolocated threads ( 2400 , 2402 ). Pressing the first pin ( 2400 ) reveals that this message thread is the original Hacker Dojo thread seen earlier.
In FIG. 25 , pressing the second pin ( 2402 ) reveals the heading of the user's new communication thread post.
In FIG. 26 , the user has switched away from satellite photographic view back to map view to show the push pins corresponding to the two message threads ( 2400 ), ( 2402 ) more clearly. Note that the curve of the road matches the photograph of the road previously seen in FIGS. 24 and 25 .
FIG. 27 shows what the user's new thread post looks like to other AskLocal users. | Communication by location method that geoplaces asynchronous message threads to a specific first geographic location geo-fence within which they are visible, and a second sub geo-fence for replies. This geopinning process may be done by remote users. The message threads have a first viewing distance parameter, a second reply parameter, and other parameters. Users with mobile devices such as GPS equipped smart phones may set their devices to discover message threads that are within a specified radius of the actual device itself, or a device virtual map location, allowing very distant threads to be viewed. However only users with a real geographic proximity to the thread within the specified reply distance may reply to the thread. The method will generally be implemented by software residing on mobile devices and host servers, and may additionally use data from map servers to place the treads in a map context. | 7 |
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Grant No. GM 13235 awarded by the National Institutes of Health.
This application is a continuation-in-part application of U.S. Ser. No. 07/557,227, filed Jul. 24, 1990 (now abandoned), which is a continuation-in-part application of U.S. Ser. No. 07/444,179, filed on Dec. 1, 1989, now issued as U.S. Pat. No. 5,051,569.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in promoting the rate of association for high specificity binding pairs used in a variety of industrial, research and medical applications. These pairs include enzyme/substrate, complementary polynucleotide and antibody/antigen combinations. In one specific embodiment, this invention relates to the acceleration of nucleic acid hybridization by heterogeneous nuclear ribonucleoproteins [hnRNPs]. In another specific embodiment, this invention relates to the acceleration of nucleic acid hybridization by a cationic detergent.
2. Information Disclosure
The acceleration of annealing between complementary nucleic acids has been described. Christiansen C. and Baldwin, R. L., 1977, Catalysis of DNA Reassociation by the Escherichia coli DNA Binding Protein, J. Mol. Biol. 115:441-454; Weinstock, G. M. et al., 1979, ATP-dependent renaturation of DNA catalyzed by the recA protein of Escherichia coli, Proc. Natl. Acad. Sci. 76:126-130; Cox, M. M. and Lehman, I. R., 1981, Renaturation of DNA: a novel reaction of histones, Nucleic Acid research 9:389-399; Keener S. L. and McEntree, K., 1984, Homologous pairing of single-stranded circular DNAs catalyzed by recA protein, Nucleic Acids Research 12:6127-6139; and Bryant, F. R. et al., 1989, Kinetic Modeling of the RecA Protein Promoted Renaturation of Complementary DNA Strands, Biochemistry 28:1062-1069.
Heterogeneous nuclear particles was known and reviewed by Dreyfuss, G., et al., March 1988, Heterogeneous nuclear ribonucleoprotein particles and the pathway of mRNA formation, TIBS 13:86-90 and Bandziulis, R. J. et al., 1989, RNA-binding proteins as developmental regulators, Genes & Devel. 3:431-437.
The A1 core protein has been implicated in helix-destabilization. Williams, K. R. et al., 1985, Amino acid sequence of the UP1 calf thymus helix-destabilizing protein and its homology to an analogous protein from mouse myeloma, Proc. Natl. Acad. Sci. USA 82:5666-5670. The cDNA encoding A1 hnRNP from rat has been cloned and expressed. Cobianchi, F. et al., 1986, Structure of Rodent Helix-destabilizing Protein Revealed by cDNA Cloning, J of Biol. Chem. 261:3536-3543. The A1 hnRNP from human cells has been isolated and purified. Kumar, A. et al., 1986, Purification and Domain Structure of Core hnRNP Proteins A1 and A2 and Their Relationship to Single-stranded DNA-Binding Proteins, J. Biol. Chem. 261:11266-11273. Kumar et al also reported on the ability of A1 hnRNP to mediate duplex formation between synthetic polynucleotides.
The characterization of mammalian A1 hnRNP was described by Cobianchi, F. et al. 1988, Mammalian Heterogeneous Nuclear Ribonucleoprotein Complex Protein A1, J. Biol. Chem. 263:1063-1071 and by Merrill B. M. et al., 1988, Phenylalanines That Are Conserved among Several RNA-binding Proteins Form Part of A Nucleic Acid-binding Pocket in the A1 Heterogeneous Nuclear Ribonucleoprotein, J. Biol. Chem. 263:3307-3313.
SUMMARY OF THE INVENTION
This invention relates to a method for accelerating the association rate constant for members of primary binding pairs in the absence of aggregate formation by the primary binding pairs, said method comprising (a) attaching complementary members of secondary binding pairs to the members of primary pairs where the secondary binding pairs have a k a larger than the k a of the primary binding pairs; and (b) placing the members in a solution under conditions which permit binding between members of the primary binding pair. The increase in the association rate is preferably at least about 10 times and more preferably at least about 100 times. The preferred primary binding pairs are selected from the group consisting of complementary polynucleotides; antibody and corresponding antigen; and, enzyme and its substrate. The secondary binding pairs are preferably selected from the group consisting of: hydrophobic polymers such as long chain alkyl groups or polypeptides containing hydrophobic residues, acidic and basic polymers containing multiple glutamic or aspartic acid and lysine or arginine residues, and acidic and basic polymers such as nucleic acids and nucleic acid binding proteins containing repeating units. The complementary secondary binding pair members can be bound to the primary binding pair members through a covalent or noncovalent (e.g., ionic or hydrophobic bonds) interaction.
In a preferred embodiment, the complementary secondary binding pair consists of oppositely charged polymers, and the primary binding pair consists of an antibody and corresponding antigen. In another preferred embodiment, the complementary secondary binding pairs are heterogeneous ribonucleoproteins and the DNA backbone and the primary binding pairs are complementary polynucleotides. In another preferred embodiment, the primary binding pairs are complementary nucleic acid and the secondary binding partner is a cationic detergent attached noncovalently to the nucleic acid backbone. In yet another preferred embodiment, the complementary secondary binding pairs are comprised of polypeptide segments having multiple positively charged groups and polypeptide segments having negatively charged groups. These polypeptide segments may comprise multiple arginine, lysine, glutamic acid or aspartic acid residues. The polypeptide segments are typically between about 100 to about 500 angstroms long and more typically about 10 to about 100 angstroms in length.
This invention further comprises compositions consisting of a member of a primary binding pair covalently bound to a member of a secondary binding pair where the members of the second pair exert a force of attraction for each other which exceeds the force that the primary binding pair members attract upon each other at a distance which permits more than one member to compete for a single binding site on a complementary member of primary binding pair. In an analogous embodiment, the composition comprises a first primary binding pair member covalently bound to a secondary binding pair member which functions to attract a second and complementary primary binding pair member unmodified by a distinct secondary binding pair member. This attraction can be via a natural or preexisting high probability binding site or domain on that primary binding pair member. Alternatively, the primary binding pair member may comprise a domain of a single charge or moiety which can exert a mutual attraction between itself and the secondary binding pair member covalently bound to the first primary binding pair member. This avoids having to modify both primary binding members. It is preferred that the secondary binding pair members or members sites have association rate constant which exceeds the association rate constant of the primary binding pairs. A preferred embodiment encompasses secondary binding pairs which comprise polypeptide segments having multiple positively charged groups and polypeptide segments having multiple negatively charged groups. Preferred primary binding pairs include antibodies and their corresponding antigens, enzymes and their substrates, and complementary polynucleotides.
This invention further provides methods for accelerating the association rate constant for members of a primary binding pair binding in the absence of aggregate formation by the primary binding pairs said method comprising (a) contacting an aqueous solution containing the members with a multivalent association rate enhancer having the ability to physically bind to each other and/or to more than one of the members of the binding pairs; and, (b) incubating the binding pairs under conditions which permit association of the binding pairs and the multivalent rate enhancers. A preferred embodiment encompasses complementary polynucleotides as primary binding pairs and either A1 hnRNP or polylysine as the multivalent rate enhancers.
In a more specific embodiment, this invention provides for a method for accelerating the rate of hybridization between two complementary nucleic acid sequences in an in vitro nucleic acid hybridization assay comprising: (a) hybridizing two complementary nucleic acid sequences in a hybridization reaction mixture under conditions permitting nucleic acid hybridization where the reaction mixture comprises heterogeneous nuclear ribonucleoprotein having a carboxy terminus capable of nucleic acid:hnRNP/nucleic acid:hnRNP interaction, said ribonucleoprotein present in an amount sufficient to substantially accelerate the rate of hybridization above the hybridization rate in the absence of the ribonucleoprotein; and (b) detecting the hybridization of the two complementary nucleic acid sequences. In a second embodiment, there is an optional proviso that neither of the nucleic acid sequences being detected is a polyribouridylic acid. In a preferred embodiment, the ribonucleoprotein may be A1 core protein or UP1. Mammalian ribonucleoproteins, such as rat, are preferred. It is preferred that the ribonucleoprotein's carboxy tail be glycine rich. The amount of heterogeneous ribonucleoprotein should be at least about a 5 fold excess by weight of the total amount of nucleic acid in the reaction mixture. The nucleic acids are preferably longer than 25 bases and can be either DNA or RNA.
In yet another embodiment, this invention provides for a method for accelerating the association rate constant for members of a primary binding pair in an enzyme reaction said method comprising (a) by attaching a polymer to the enzyme, said polymer binding with high probability to the substrate such that the polymer and substrate have a k a larger than the k a of the enzyme and substrate; and (b) placing the members in an aqueous solution under conditions which permit binding between members of the primary binding pair. In a preferred embodiment, the polymer contains multiple positively charged groups, such as multiple lysine residues, and the enzyme is a nuclease and the substrate is a polynucleotide. The preferred nucleases include restriction endonucleases and ribozymes.
In another embodiment, this invention provides for a method for conducting a high temperature nucleic acid hybridization assay having a target nucleic acid and a probe nucleic acid comprising: (a) hybridizing two complementary nucleic acid sequences in a hybridization reaction mixture under conditions permitting nucleic acid hybridization, including temperatures at about 45° C. or above, where the reaction mixture comprises single stranded nucleic acid binding compounds present in an amount sufficient to substantially accelerate the rate of hybridization above the hybridization rate in the absence of the compound and where the numbers of probe nucleic acid to target nucleic acid does not approximate a 1 to 1 ratio; and (b) detecting the hybridization of the two complementary nucleic acid sequences. In a preferred embodiment, the compound is a heterogeneous ribonucleoprotein, the high temperature is preferably about 65° C., and the nucleic acid is DNA.
This invention also provides for kits encompassing multiple compartments for the various reagents needed to use the invention as described herein. These include kits having compartments with primary binding pairs such as nucleic acids or antibodies, compartments with hybridization reagents, and compartments with secondary binding pairs such as heterogeneous nuclear ribonucleoproteins having a glycine-rich carboxy terminus. Where the kit further comprises nucleic acids as primary binding pairs, the nucleic acids can be labelled with a reporter such as an enzyme or a fluorophore.
DEFINITIONS
"A force of attraction for each other which exceeds the force that the primary binding pair members attract upon each other at a distance which permits more than one member to compete for a single binding site on a complementary member of primary binding pair" functionally describes the minimum amount of attraction necessary to use the claimed method. The actual force is typically determined empirically by the methods described herein.
"A1 core protein" refers to a protein of approximately 34 kD which is found associated with hnRNA in the nucleus of eucaryotic cells and which is composed of two consensus nucleic acid binding domains and a glycine-rich carboxy terminus.
"Aggregate formation" refers to a reaction where primary binding pairs are binding into a stable complex of members, in substantial excess of two. Typically this reaction is detected by the presence of insoluble particles which either precipitate out spontaneously or are removable by filtration or centrifugation.
"Antibody and corresponding antigen" refers to an antibody and the antigen to which it binds.
"Association rate constant" refers to the rate at which complementary members of a binding pair form a complex. It is measured in liters of complex formation per mole per second. For the case where two molecules are coming together to form a complex, (e.g., A+B ←→AB), the rate of formation is equal to k a [A][B]. [A] is the concentration of A in solution, [B] is the concentration of B in solution, and k a is the association rate constant. Lower rates of association exist where there is little mutual attraction over significant distances and where complex formation averages multiple random collisions between members before complex formation occurs. Binding members having low k a rely on Van der Waal forces or hydrogen bond formation to provide the energy of complex formation. High rates of association exist where the members mutually attract each other to bring about a greater number of contacts which increase the opportunity for complex formation. Such binding members rely on electrostatic and hydrophobic interactions.
"Carboxy terminus" refers to that half of a polypeptide bearing the free α-carboxy group.
"Cationic detergent" refers to a detergent having a positively charged group and a hydrophobic domain. Examples include cetylpyridinium chloride, dodecyltrimethylammonium chloride, hexadecyltrimethylammonium chloride and tetradecyltrimethylammonium bromide.
"Complementary members" refers to any two molecules which can bind to each other and unless otherwise limited encompasses both high and low specificity binding pairs and high and low probability binding pairs.
"Covalently bound" refers to a bond between two atoms where a pair of electrons are shared.
"DNA backbone" refers to the phosphate groups which typically impart an overall negative charge to a nucleic acid.
"Nuclease" refers to an enzyme which cleaves the phosphodiester bonds of nucleic acid. This term embraces ribozymes and restriction endonucleases.
"Glycine rich" refers to polypeptides or regions of polypeptides which comprise about 20 to 80% glycine residues.
"Hydrophobic polymers" are those polymers which comprise units that are less polar than water and tend to associate with other hydrophobic polymers in an aqueous environment.
"In an amount sufficient to substantially accelerate" is a quantity which is empirically determined by the methods described herein and where "substantially accelerate" refers to a statistically meaningful increase.
"Multivalent association rate enhancer" refers to a macromolecule such as A1 hnRNP which has multiple sites with which it may either bind with high probability to other multivalent association rate enhancers and/or to the primary binding partners. These macromolecules also enhance or increase association rates for primary binding partners as described herein.
"Negatively or positively charged groups" refers to moieties on a polymer such as carboxyl, phosphate, or amine groups.
"Nucleic acid sequences" refers to nucleic acids in a polymeric form. Typically this is the naturally occurring 5'-3' ribose phosphate backbone. Both natural and synthetic polymers are operable in this invention. Such synthetic polymers would include unnatural bases and variations in the natural 5' to 3' bonding. The size of the sequence is not critical. Typically the polymers are of a size to permit hybridization to be sufficiently specific to function successfully in the assay and avoid nonspecific binding to non-targets. Preferably the polymers are from about 25 nucleotides long up to several kilobases. Exact complementarity between strands is not required. By varying the stringency of the hybridization mixture, one can achieve satisfactory results with strands of nucleic acid that are not exact complements of each other.
"Polymers" when described as either acidic or basic encompass molecules of repeating units which are either uniform or at least about 10% units which bear at least one proton releasing (acidic) or protein accepting group (basic). Examples include polyglutamic acids and polylysine.
"Polymer binding with high probability to the substrate" refers to a polymer with a repeating structure, each unit of which can bind independently to the substrate with low affinity, using electrostatic interactions and/or hydrophobic interactions.
"Polypeptide segments" refers to amino acid chains linked by peptide bonds.
"Primary binding pairs" refers to a ligand/receptor combination in which the members interact in a highly specific manner without significant mutual long distance forces of attraction so that at concentrations where members are at an average distance apart where multiple members can compete for a given opposite member, random motion dominates the probability that any one member will bind to a particular complementary member.
"Protein members" refers to binding pair partners which comprise at least 70% amino acid residues.
"Oppositely charged polymers" refers to polymers which are capable of attracting each other through positive and negative ionic forces.
"Reporter" refers to substituents or moieties that are detectable and act as signals or labels in binding assays to permit the presence or absence of the entity to be assayed. These include enzyme labels, radioactive labels and fluorescent labels.
"Residues" when referring to an amino acid, e.g., lysine, encompasses the specified amino acid although a part of the peptide chain.
"Secondary binding pairs" refers to a ligand/receptor combination in which the members interact in a relatively nonspecific manner and where the members exert a significant long distance mutual attraction upon each other.
"Single-stranded nucleic acid binding compounds" refers to substances which associate with nucleic acid of any sequence and are able to function as secondary binding pair members. These include cationic detergents and single stranded nucleic acid binding proteins (hnRNP).
"Solid support" refers to an insoluble entity to which binding members can be attached in a manner in which they can still bind to their complementary partners.
DETAILED DESCRIPTION
This invention provides for a valuable means for increasing the association rate constant for two members of a high specificity binding pair (primary binding pair). Means to increase the rate of association between binding pairs is of great importance to industry, medicine and research.
The purpose of this invention is to increase the rate of association for highly specific biological binding partners. The primary binding partners are ligand/receptor pairs which do not exert a strong mutual attraction for each other over distances which exceed their combined radius. Initial interactions between primary binding partners are primarily due to random movement within the medium (typically a buffered aqueous solution). Once two primary binding partners are in sufficiently close proximity to engage strong intermolecular attraction, binding is assured. Examples of primary binding pairs are DNA/DNA complementary binding pairs, enzyme/substrate binding pairs, antibody/antigen binding pairs and hormone/receptor binding pairs.
Examples of procedures where relying upon interactions between high specificity binding pairs is required include: (a) nucleic acid hybridization assays such as southern and northern assays, subtraction hybridization, polymerase chain reaction assays, ligase amplification assays, ligation mediated detection assays and RNAase protection assays; (b) antibody: antigen complex formation for ELIZA assays, radioimmunoassays, immunoprecipitations, western blots, and cancer chemotherapy; and, (c) enzyme mediated catalysis such as nucleolytic attack, proteolysis, and catalysis of small molecule conversion.
The interaction of molecules in solution is limited by the rate with which the interacting components diffuse to within a distance sufficient for a binding interaction to occur. This distance is a function of the size and the nature of the binding site through which the molecules interact.
The binding sites of most macromolecules are highly specific for their ligand. They take advantage of various physical forces, including electrostatic forces, hydrogen bonds, Van der Waals forces, and hydrophobic interactions.
I. ASSOCIATION RATE CONSTANTS
The association rate constant for binding of molecules can vary, depending on the types of interactions involved and the rate of diffusion of the interacting components. High specificity interactions generally take advantage of all forces. However, electrostatic forces and hydrophobic interactions will act over longer distances in solution and are often responsible for the initial attraction between members leading to a specific binding interaction which results from the increase in affinity as distance between binding pairs decreases. Complex formation of binding pairs results from the formation of specific contacts mediated through all physical forces (e.g., hydrogen bonding, electrostatic, hydrophobic and Van der Waals forces). This two phase process can be outlined as: ##EQU1##
Only the rate of formation of the encounter complex is dependent upon the concentration of reactants, P and A, in solution. For most interactions, the reaction is limited by the rate with which components encounter each other in solution, which is k1(P)(A). If k2 is fast with respect to k1, and greater than the initial dissociation constant, k-1, the rate with which complex formation takes place will be determined by the rate of diffusion, which is taken as:
k.sub.D =4 pi N.sub.A (D.sub.P +D.sub.A)r.sub.PA
N.sub.A =Avogadro's Number
D.sub.P, D.sub.A =Diffusion Coefficients
The distance at which the molecules interact, r PA , is a function of the binding interaction which takes place at the greatest distance in solution, and can lead to the formation of the high affinity complex. The k D for the association of two large molecules (proteins, DNA) in solution are typically 10 8 /M/s. For the interaction of a large and a small molecule (enzymes:substrates), the rates are 10 9 /M/s. If the initial interaction between components does not include forces which act at a distance (e.g., complementary electrostatic interactions or hydrophobic forces), and instead, relies on forces which are mediated over short distances (e.g., hydrogen bonds or Van der Waals forces), the rpA and therefore the k D of the association will be considerably less. Increasing the distance at which these molecules can interact can be expected to give a corresponding increase in the rate of association, provided that the interaction at a distance can lead to the more specific association. Proteins by Thomas E. Creighton (1983) W. H. Freeman and Co. Chapters 4,8 offers a good conceptual review of association rate constants.
Because this invention involves increasing association rate constants for a variety of binding pairs, measurement of such rate constants is helpful to optimize assay conditions. Association rate constants can be calculated in a variety of accepted and well-known ways:
1) Nucleic Acid Hybridization
Under conditions where little strand melting occurs (i.e., below the melting temperature of the nucleic acid) the rate of annealing can be calculated by measuring the amount of loss of single stranded substrate at various times, or by measuring the amount of formation of double stranded product. The amount of single strands can be measured by S1 nuclease sensitivity assays. The amount of double stranded material can be measured by hydroxyapatite binding. Optical hyperchromicity can also be used. Alternatively, single strands can be separated from double strands by gel electrophoresis by virtue of their different mobilities. For DNA molecules with defined ends, the association rate constant for annealing can be derived from the equation: ##EQU2##
2) Antibody:Antiqen Interactions
Antibody:antigen interactions generally have association rate constants of 10 8 M -1 s -1 . These have been calculated by absorption spectroscopy, Using methods such as relaxation or stopped flow. Equilibrium association constants for antibody:antigen interactions can vary from less than 10 4 for weak association, to greater than 10 8 M -1 (CRC Critical Rev. Immunology (1986) 6: (1)p1-46)
3) Enzyme:Substrate Interactions
For reactions where the enzyme is not saturated with substrate (where an addition of substrate leads to a more rapid rate of product formation), an increase in the rate of association of enzyme with substrate would be expected to lead to increased product formation. Enzyme:substrate interactions are generally rapid, with association rate constants between 10 7 -10 9 . Because of this, sophisticated methods of obtaining data to calculate rate constants are used. These include:
(a) Rapid Mixing Techniques Using
A Continuous flow apparatus
Stopped-flow spectrophotometry
Rapid quenching to stop the reaction
(b) Flash Photolysis to generate substrate in a premixed solution
(c) Relaxation methods, such as
Temperature jump experiments
(Enzyme Structure and Mechanism Alan Fersht, W. H. Freeman (1985)
This invention takes advantage of a specific class of binding pairs termed high probability binding sites. These binding members utilize electrostatic and hydrophobic interactions to provide a greater force of attraction between binding pairs at a distance. When such molecules are attached either directly or indirectly to members of a binding pair having a high specificity for each other, there is a significant increase in the association rate constant for the high specificity binding interaction.
II. SECONDARY BINDING PAIRS
With the above explanation of complex formation between binding pairs, the following definition is offered as a guide for the selection of those binding pairs (secondary binding pairs) which will function to increase the apparent association rate constant of the high specificity binding pairs or primary binding pairs. For purposes of this discussion, the secondary binding pairs preferably are members which interact with their complementary member over a relatively great distance through electrostatic or hydrophobic interactions with complex formation being relatively non-specific and occurring with a high degree of probability upon initial contact.
The properties which identify the secondary binding pairs, with their high probability binding sites, include binding sites which are relatively homogeneous with respect to the type of interacting chemical group such that any part of one binding site can react with any part of the corresponding binding site. An example of binding partners with homogeneous binding sites would be a binding member comprised of a polymer having multiple positive charges and a complementary partner that is comprised of multiple negative charges. Another possibility would be to have both secondary binding pair members be hydrophobic. Hydrophobic binding partners can be composed of multiple hydrophobic amino acid residues, such as leucine or isoleucine. They can be interspersed with amino acids which destabilize secondary structure to promote an extended, flexible configuration. One could also construct a repeating unit which would incorporate both electrostatic and hydrophobic constituents. In this way, complex formation is relatively nonspecific and arises when any part of one binding pair contacts any part of its complementary binding pair.
The binding of the secondary binding pair functions to spatially orient the members of the primary binding pair in close proximity to each other. This increases the probability, and therefore the rate of binding events between the primary binding pairs which typically exert less mutual attraction on each other than the secondary binding pair at relatively large distances. By "relatively large distances", it is meant that the distance is such that primary binding is not assured, and could still be disrupted by random thermal motion. In other words, it is meant that the distance is of a sufficiently large radius that more than one member can compete for a particular binding site on a corresponding partner. As primary binding sites get increasingly close, the binding forces which attract them together can become greater than the binding force of the secondary binding interaction. This would generally occur on the order of a few angstroms. The secondary binding pairs are designed such that they can interact even when the primary binding sites are tens of angstroms apart.
The binding sites on the members of the secondary binding pairs should be physically large. A relatively large site will increase the probability of a binding event between the secondary binding pairs. Enlarging the size of a binding site would involve the addition of more repeating units to the binding site. An example of enlarging the binding site would be to increase the length of secondary binding pairs comprising polylysine and polyglutamate from tripeptides to decapeptides. It should be noted that the size of the secondary binding sites could be optimized so as to maximize the rate of formation of the primary binding interaction once the secondary binding interaction has occurred. The size should not permit the primary binding pair to separate beyond the average distance which exists between noninteracting primary binding pairs in solution, when the secondary binding pairs are interacting with each other.
The secondary binding members are preferably composed of flexible tails. Flexible structures offer several advantages. These tails allow corresponding binding sites to interact from any orientation in solution. If a binding site was on one face of a globular protein, only that face would be a potential binding partner. In addition, flexible secondary binding pairs allow for orientations and associations of the high specificity binding members, through brownian motion, without requiring dissociation of the secondary binding pairs. Flexible tails could be ensured by incorporating chemical constituents which are themselves flexible, or which are unlikely to fold into a globular structure. Secondary binding members with this property include polypeptides incorporating glycine and proline residues, long alkyl chains (of about 5 to about 20 carbons), and synthetic polymers such as dextran sulfate.
The secondary binding pairs should have a mutual attraction which operates over the longest possible distance and in any orientation. This could be achieved by using charge:charge interactions or hydrophobic constituents. Charge:charge interaction involve moieties having positive charges such as mono or polyprotic bases (e.g., amino groups or metal ions) and negatively charged moieties such as mono or polyprotic acids. The charged region can be uniformly composed of charged amino acids or have such amino acids randomly inserted so that the interacting domains are capable of binding to each other. Hydrophobic interaction is illustrated by long alkyl chains. While these types of interactions inherently provide a mutual attraction over a relatively long range, incorporating them into a long, flexible tail would provide for an even greater increase in their ability to mutually attract over distances. Amino acids which are charged or which have hydrophobic character are well known.
The use of multiple high probability binding members attached to each member of the primary binding pair can facilitate the complex formation between members of the primary binding pair. This would increase the likelihood of a binding partner undergoing a high specificity binding event. For example, for processes such as nucleic acid annealing, multiple high probability binding partners such as multiple A1 hnRNP proteins attached along the DNA molecule might allow multiple high probability interaction events, thereby increasing the likelihood of a productive nucleation event. In this case, the length of the individual secondary binding pairs can be shortened, as the effect of having multiple secondary binding pairs on a polymer, which is itself flexible, allows the entire molecule to act as a secondary binding partner.
Using the methods described below, one can design the specific placement of the high probability binding site so as to increase the proximity of the high affinity binding sites of the primary binding pair once the high probability reaction takes place. For example, the high probability binding site could be attached near the active site of an enzyme so as to channel the substrate to the active site.
It would also be preferred to attach several small high probability binding partners along the backbone of a nucleic acid strand, rather than have one large high probability binding partner at the end of a strand, as this configuration would be more likely to cause an alignment of the strands after initial association had occurred, thereby further increasing the proximity of nucleotides on opposite strands, and thereby increasing the rate of specific association. It is preferable that initial binding of the primary binding pair can be achieved without complete dissociation of the secondary binding pair members.
Under certain conditions, high probability interactions can occur between secondary binding pairs without high specificity binding potential. An example of this is when non-complementary A1 hnRNP coated nucleic acid strands interact with each other in solution. If noncomplementary strands associate too stably with each other, they will be prevented from associating with their complementary partners. Thus, it is important to use secondary binding pairs which do not interact with each other to form a complex which is excessively stable. It is better to have secondary binding members interact with each other with high probability, but relatively low stability.
Two general approaches are particularly useful to lower the stability of these secondary binding partner interactions. One is to change the chemical nature of the secondary binding partners, and the other is to change the aqueous environment. For example, the size of the secondary binding members could be reduced, which would lower the stability of these interactions. This would not be preferred, as it would also lower the probability of a binding event. A better method would be to introduce chemical constituents which destabilize the interaction. This could be done, for example, by replacing charged groups with neutral groups. A secondary binding member composed of polylysine could have some of the lysine residues replaced with glycine or proline. In addition, when reactions are carried out in vitro, buffer conditions could be altered so as to increase or decrease the strength of the high probability binding reaction. Increased ionic strength would lower the stability of interactions between secondary binding partners composed of charged residues. Changes in the temperature could also influence the nature of the reaction. High probability interactions should be such that the likelihood of a high specificity binding interaction is great once a high probability interaction has occurred, but sufficiently transient such that, in the absence of high specificity binding potential, dissociation takes place. Because most secondary binding members don't require a specific, stable structure in order to function, high temperatures generally do not inhibit their ability to promote rapid association. Maximal rates are likely to be achieved at temperatures just below the temperature where the primary binding interaction becomes unstable.
For example, when accelerating nucleic acid hybridizations using cationic detergents such as an alkyltrimethyl ammonium bromide, those of skill would recognize that low temperatures of approximately zero degrees celsius can cause aggregation. (Manfioletti, G. et al., 1988, Nucl. Acids Res. 16:2873-2884). Nonspecific aggregation is not desired and can be avoided by the use of increased incubation temperatures, preferably 60°-90° C.
The following are examples of secondary binding pairs which have high probability binding sites:
(a) Negatively charged: dextran sulphate, polyphosphate, polyglutamic acid and polyaspartic acid;
(b) Positively charged: polylysine, polyarginine and polyethylenimine;
(c) Hydrophobic, polyphenylalanine and polytryptophan and polyalkanes.
High probability binding sites can be chemically synthesized and attached to the appropriate macromolecules. Alternatively, polypeptide coding sequence, either naturally occurring or designed using the properties listed above, could be incorporated into a gene whose product contains a high specificity binding site. In addition, high probability binding sites could be attached non-covalently to the high specificity binding partners.
This invention can be performed in three different embodiments. The first embodiment utilizes a secondary binding pair which comprises two different members. These two members exert a mutual attraction upon each other and are illustrated by a polyglutamate and polylysine members. The second embodiment utilizes two identical members which mutually attract each other. Polymers which are hydrophobic such as long chain hydrocarbons (e.g., pentane, octane, etc.) will mutually attract each other in a manner similar to micelle body formation. The third embodiment uses a single multivalent macromolecule capable of high probability binding attached to one of the primary binding partners to increase the apparent association rate constant. The attachment can be through a covalent bond. Charged polypeptides, when covalently bound to nucleic acid, illustrates this third embodiment. The third embodiment is also illustrated by primary binding partners comprised of an antibody and an antigen, where the antigen is a virus particle, and the antibody has attached to it a secondary binding partner with high probability binding affinity to the repeating structure of the virus coat.
The members of the primary and secondary binding pairs may be covalently or noncovalently bound to each other. Where covalent, the bonding may be direct or through a linking agent. Direct linking is done via available groups which react with each other such as peptide linkages between amine/carboxyl groups, Schiff's base formation between aldehydes and amines, esterification between alcohol groups and acids and disulfide bond formation as between cysteine residues. Linking reagents are either homobifunctional or heterobifunctional compounds such as glutaraldehyde, N-hydroxy succinimidyl (NHS) esters or α-bromoacetamide. These reagents are commercially available from a variety of sources. There use is well known. See for example U.S. Pat. Nos. 4,152,411 and 4,687,732 which are incorporated herein by reference. These two patents illustrate means for covalently binding members of primary binding pairs to labels. The general teachings and methods are applicable to the covalent linking of members of a primary binding pair to members of a secondary binding pair.
If the primary and secondary binding members are bound through noncovalent means, the strength of their bond must be sufficient to ensure that at least one secondary binding member is bound to a primary binding member at most times.
III. APPLICATIONS OF SECONDARY BINDING PAIRS FOR INCREASING THE ASSOCIATION RATE CONSTANT FOR PRIMARY BINDING PAIRS
The use of secondary binding pairs has wide use in processes where the kinetics of chemical reactions involving binding of separate molecules in solution is rate limiting. These include binding reactions, such as nucleic acid annealing, as well as increasing the rates of chemical reactions. This invention has in vivo and in vitro applications. The following is a short list for the purpose of illustration only. Any reaction which is limited by the bringing together of components might be facilitated by this invention.
1) Nucleic Acid Annealing.
Nucleic acid annealing is limited by the rate of nucleation events occurring in solution. When secondary binding members with high probability binding sites are attached to nucleic acid strands, such that the binding site on one strand has a complementary partner on the complementary strand, an increased rate of association of the complementary nucleic acid strands in solution is achieved. If this association is such that the probability of a correct nucleation event is increased, the kinetics of annealing will be increased. A1 hnkNP protein, in part, facilitates annealing in this way. It is important that the complementary strands are able to move with respect to each other once high probability binding takes place so as to allow the possible association of many different pairs of bases on complementary strands so that the likelihood of a correct association is increased. In the absence of stable, high affinity base pairing, the complex dissociates.
A second example of nucleic acid annealing would be to attach a positively charged high probability binding site directly to a probe nucleic acid. This would cause a rapid, but flexible, association of the probe with target nucleic acid, thereby increasing the rate of specific association.
2) Antibody:Antigen Interactions
The attachment of a high probability binding site to an antibody and a complementary high probability binding site to its corresponding antigen would promote the specific antibody:antigen binding event. Additionally, the attachment of a high probability binding site to one antibody could be used to increase the rate of association of a second antibody with a complementary high probability binding site, to a different epitope of the same antigen. One antibody could be present in high concentration, while the second antibody could be present in low concentration. This second antibody, which could be labeled or carry a toxic compound, would then bind rapidly to any antigen to which the first antibody has already been attached. The antigen could be a protein with two different epitopes, one for each antibody. Alternatively, the antigen could be a cell which has on its surface two different proteins, each with an epitope for one of the antibodies.
When the antigen itself is composed of a repeating unit, a high probability binding partner can be attached solely to the interacting antibody molecule. The high probability binding partner would interact with the antigen with high probability, but low specificity, and thereby increase the rate with which the high specificity antibody molecule associates with the antigen. The antigen could be a virus particle with multiple identical coat proteins on its surface, or a polymeric protein such as actin. The high probability binding partner could be a small, repeating unit of a naturally occurring binding site for the antigen, or it could be a synthetic high probability binding partner. For the case of the AIDS virus (HIV), the high probability binding partner could be composed of a repeating unit of the amino acid sequence [Phe, Leu, Thr, Lys, Gly, Pro] which has been implicated in the binding of HIV to the CD4 receptor (Peterson, A. and Seed, B. (1988) Cell 54, 65-72). The high specificity binding partner could be an antibody, or other equivalent receptor molecule with high specificity binding potential. In the case of HIV, the high specificity binding partner could be the cellular receptor CD4, or a soluble variant thereof.
3) Nucleic Acid Modifying Enzymes
A secondary binding member having high probability binding sites is attached to an enzyme which modifies nucleic acid, such as a restriction enzyme, nuclease, polymerase, or other DNA modifying enzyme. The high probability binding site increases the frequency with which the nucleic acid modifying enzyme interacts with the nucleic acid thereby increasing its efficiency. A positively charged, high probability binding tail, such as polylysine or polyarginine, would be expected to interact with the negatively charged backbone of DNA. A similar tail could be used for enzymes which modify RNA. This embodiment eliminates the need for attaching a corresponding high probability binding site on the nucleic acid substrate. The nucleic acid phosphate backbone is a natural high probability binding site.
4) Proteases
A high probability binding partner which could interact with common chemical constituents on proteins could be used to increase the rate of association of a protease to its substrate. Alternatively, the high probability binding partner could be hydrophobic, so as to interact with a detergent denatured protein. If said detergent were charged, the high probability tail could also carry complementary charge to increase the kinetics of the interaction. In this way, the protease would associate with high concentrations of detergent, such as that found on a denatured protein. It may be important in this case to design a high probability binding partner which is not itself a polypeptide chain to avoid autolysis.
5) Enzyme:Smaller Substrate Interactions
A secondary binding member having high probability binding sites could be attached to an enzyme such that it bound substrate in a manner similar to the trapping of cations by DNA. The charged substrate would then diffuse along the high probability binding tail and encounter the active site of the enzyme. This would be feasible for charged substrates, and may also be useful for substrates with hydrophobic character.
A preferred embodiment encompasses the acceleration of the association rate constant for complementary nucleic acids. The following provides details of this embodiment.
IV. NUCLEIC ACID RENATURATION
A. Nucleic Acid Renaturation Using Heterogeneous Ribonucleoproteins [hnRNP]
HnRNPs are naturally occurring proteins found in ribonuclear core particles which are approximately 20 nm in diameter and have a sedimentation coefficient of about 40S. The core particles are found in a variety of eukaryotes including fruit flies, rodents and man. The core particles are comprised of both ribonucleic acid and multiple core proteins. The precise purpose of the particles or of the role of hnRNP is not presently understood. It is known that these particles are commonly associated with newly transcribed messenger RNA. It is presumed that they play a role in the splicing of the message.
The hnRNPs of use in this invention are obtained from the core proteins of the heterogeneous nucleoprotein particle. This particle is typically made up of several different core proteins ranging from 32,000 to 42,000 daltons. The core proteins of use in this invention are distinguished by their typically being the smallest protein of the group and by their carboxy termini which are capable of nucleic acid:hnRNP/nucleic acid:hnRNP intermolecular attraction. The determination of nucleic acid:hnkNP/nucleic acid:hnRNP interactions is made through routine titration experiments where acceleration of annealing is measured (see example section).
One can identify hnRNP proteins of use in this invention by passing a protein extract over a single stranded DNA column, and isolating proteins which bind to the column by elution with increasing salt concentrations. This eluate will accelerate hybridization, with A1 hnRNP protein being particularly effective. Proteins which lack significant secondary structure by circular dichroism measurements would also be expected to be particularly useful. Alternatively, one can predict in some hnRNP core proteins which will accelerate hybridization by identifying the presence of a glycine-rich (approximately 40%) COOH terminus. The determination of a glycine rich termini is made by comparing the number of glycines present in the first half of the protein with the second half. (J. Biol. Chem. 263:3307-3313, 1988).
A preferred hnRNP is a human core protein typically designated A1 hnRNP. It may be obtained as a naturally occurring protein by purification from HeLa cells or as a heterologous expression product by isolation from a genetically engineered cell expressing the A1 hnRNP gene or cDNA.
The preferred method of isolating natural-occurring hnRNP is as described in detail by Kumar et al. J. Biol. Chem. 261:11266-11273, 1986. In brief this method involves the isolation of the 20-nm monoparticles from purified nuclei. The monoparticles are isolated in a sucrose density gradient. Core protein A1 is obtained by one-step chromatographic procedure which relies on the inherent tendency of the other core proteins to aggregate into polymorphic forms. The 40S particles are dialyzed into a buffer of 2.0M NaCl to dissociate the particles. The extract is further enriched with A1 by elution through a gel filtration column in the high salt buffer with SH-reagents and collecting the appropriate fraction.
Alternatively, cDNA encoding the rat A1 hnRNP gene has been cloned and the native protein purified from mouse myeloma MOPC-21 cells according to Cobianchi, et al., J. Biol. Chem. 261:3536-3543, 1986. The Cobianchi reference also provides the nucleotide sequence for the rat A1 hnRNP.
HnRNP (about 0.5 mg/ml) is fairly stable and can be stored at -80° C. in 10 mM Tris pH 8.0, 0.1 mM EDTA, 0.1 mM dithiothreitol and 1M NaCl. Repeated freeze thawing cycles are acceptable but not recommended.
The hnRNP of use in this invention function by binding to nucleic acid and by interacting in an undefined manner to facilitate hybridization of complementary nucleic acid sequences. The carboxy terminus of these proteins are required for maximal acceleration of annealing and for intermolecular interaction (hnRNP/hnRNP interaction).
The hnRNP are substantially conserved across taxonomic genera and families. Some allelic polymorphism is found within species. In addition, through recombinant genetics, one may introduce, substitute or delete various amino acids without inhibiting the ability of hnRNP to accelerate duplex formation. For example the glycine rich domain may be enriched with equivalent amino acids such as proline. This invention and the term hnRNP is meant to embrace all proteins having the functional ability to accelerate annealing between nucleic acids. These proteins embrace both naturally occurring forms and synthetically modified forms.
B. Accelerating the rate of hybridization for nucleic acid hybridization assays
Nucleic acid hybridization assays are well known in the art. This invention is not limited to any particular mode of practicing these assays. Hybridization techniques are generally described in Nucleic Acid Hybridization a Practical Approach, Ed. Hames, B. D. and Higgins, S. J., IRL Press 1987. As improvements are made in hybridization techniques, they can readily be applied to this invention.
The acceleration of nucleic acid annealing has many uses. The uses include Northern and Southern analyses, subtractive hybridization, plaque colony screening using nucleic acid probes, and the polymerase chain reaction amplification process. Clinical applications include: diagnostic assays for pathogens, and disease states; and genetic profiling for medical or forensic uses.
Hybridization Conditions
Various hybridization solutions may be employed in the reaction mixture. Standard hybridization solutions often contain protein denaturants such as detergents, polar organic solvents such as formamide or guanidine salts. Such solutions are not recommended for protein mediated assays. The preferred solutions for this invention have a pH of between about 4.0 and about 10, most preferably between pH 6 and 8. EDTA may be included in the hybridization solutions.
Standard salt conditions for hybridization assays include the use of monovalent salts (eg. potassium or sodium) in concentrations of 1 molar or greater. Under the conditions such as provided in the examples below, high concentrations of monovalent cations have been noted as inhibiting hnRNP mediated acceleration of annealing. Although hybridization conditions may possibly be varied to obtain acceleration of annealing under high salt conditions, it is recommended that the total monovalent salt concentration be kept between about 80 and 120 mM.
The hybridization solutions may optionally contain minor amounts of magnesium salts, non-specific blocking agents, such as bovine serum albumin, unlabeled carrier nucleic acids from about 0.01 mg/ml fragmented nucleic acid, DNA, e.g., fragmented calf thymus DNA or salmon sperm DNA, or yeast tRNA or yeast RNA.
The recommended quantity of hnRNP is dependent upon the quantity of nucleic acid present in the reaction mixture. The hnRNP is thought to coat the nucleic acid with multiple hnRNP bound to each strand. For effective acceleration of annealing, a minimum of a five fold excess of hnRNP by weight over the total weight of nucleic acid present in the reaction mixture is recommended. More preferred is a 10-20 fold excess of protein by weight over the total nucleic acid. Where nucleic acid conditions are very low, increased amounts of hnRNP may be required.
Reaction temperatures will influence the hybridization rates even in the presence of hnRNP. The reaction temperature conditions are between 20°-100° C. and preferred temperatures are 37°-65° C. There is a noticeable increase in acceleration of annealing as temperatures increase with 65° C. being a preferred reaction temperature for hybridization.
Modes of Hybridization Assays
Nucleic acids hybridizations may be run in a variety of modes. It is expected that one of skill is familiar with nucleic acid hybridization assays and no attempt is made here to describe in detail the various modes available to workers in the field. The acceleration of annealing with hnRNP can be achieved in both homogeneous and heterogeneous nucleic acid hybridization assays.
Homogeneous nucleic acid hybridization assays involve assays where both complementary nucleic acids are free in solution. Heterogeneous assays involve the immobilization of at least one nucleic acid polymer to a solid support. These supports include but are not limited to filter papers, gels, nylon, magnetic beads, glass, carboxy and amino activated inert solids such as teflon or plastics. Immobilization can be noncovalent through ionic or hydrogen bonding interactions or through covalent bonding. Heterogeneous assays are well known in the art.
The reaction modes include but are not limited to binary, ternary or quaternary levels. Binary modes are reactions which rely only upon annealing between two separate nucleic acids, one of which is typically labeled. Ternary and quaternary modes involve sandwich assays where multiple nucleic acid polymers are annealed to each other.
Detection of Hybridization
The hnRNP mediated annealing does not effect the means for detection of hybridization. All standard methods are useful. These include radioisotopes, fluorophores and enzymes (eg. horseradish peroxidase or alkaline phosphatase) as reporters or labels. The reporters can be either directly attached to one of the nucleic acid polymers or indirectly attached through a ligand/receptor configuration. Methods for detection are well known in the art and variations and improvements are within the scope of this invention.
C. Other Renaturing Compounds
This invention also provides for a method of accelerating hybridization at elevated temperatures (above 45° C.). The compounds of use in this method include single stranded nucleic acid binding proteins. These proteins include hnRNP and polylysine. Such proteins are known in the art as mediators of nucleic acid annealing. (See for example J. Mol. Biol. 115:441, 1977; Proc. Natl. Acad. Sci. USA 82:5666-5670, 1985 and Biochemistry 28:1062-1069, 1989). Other compounds include cationic detergents such as hexadecyltrimethylammonium bromide and dodecyltrimethylammonium bromide.
The reaction conditions are as provided are operable for hnRNP. Optimal reaction conditions may require some routine titration experiments. Undesired results are reflected by conditions which result in nonspecific aggregate formation or unaccelerated hybridization. Such results are readily monitored by routine methods known to those of skill.
D. Kits
The invention also encompasses multi-compartmented kits using the components disclosed herein for conducting the described methods. Such kits would include the secondary bind partners either attached or unattached to a primary binding partner. Primary binding members may also be included. Means for detecting or measuring binding between primary or secondary members could also be included in these kits.
All references are incorporated by reference herein. The following examples are offered by way of illustration and not by way of limitation.
EXAMPLES
1. The Promotion of Eco R1 Restriction Enzyme Binding with its Corresponding Restriction Site
Restriction enzymes are widely used tools in molecular biology. They recognize, and subsequently cleave, DNA at specific sequences. The rate with which restriction enzymes are found to associate with their corresponding binding sites can be facilitated by the addition of high probability binding partners. The Eco R1 restriction enzyme is well known. The gene encoding this enzyme is available, as are methods for modifying, overproducing and purifying the protein (see, for example Proteins 7:185-197, 1990). The crystal structure of Eco R1 is also known. (Science 234, 1526-1534, 1986). In this example, DNA sequence encoding a high probability binding site composed of a repeating unit of (Glycine3-Lysine1) is cloned into the gene for Eco R1 at the amino terminus. The number of repeating units is ten. The gene encoding this novel enzyme is expressed, and the protein purified. This enzyme is then used to bind to fragments of DNA containing the sequence GAATTC. These fragments are 50 and 1000 base pairs in length. Binding is measured by known techniques (PNAS 79:4010-4014, 1982). The monovalent cation concentration is titrated to optimize for the rate of association of the protein to the nucleic acid. Under some conditions, the rate of association is faster for the Eco R1 enzyme containing the high probability binding site. Magnesium is also included in the reaction to promote cleavage. This is an example of the third embodiment as described above.
2. The Acceleration of Nucleic Acid Hybridization Using A1 hnRNP
A comparison of nucleic acid hybridization rate in the presence of A1 hnRNP and in its absence demonstrates the dramatic hnRNP mediated increase in the rate of hybridization. The assays used nucleic acid from a Hind III/Bgl II digestion of plasmid pSV2gpt (Science 209:1422-1427, 1980). This double stranded segment has 120 nucleic acid bases per strand and comprises a DNA segment adjacent to the xanthine guanine phosphoribosyl-transferase gene from E. coli. Both strands were end labeled with 32 P by filling the recessed 3' ends according to Maniatis, T., Fritsch, E. F., and Sambrook, J., 1982, Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. [Maniatis] (at page 113). The count was approximately 10 8 cpm per microgram of nucleic acid.
The nucleic acid was placed in a hybridization reaction mixture of 20 μl containing, 10 mM potassium phosphate pH 7.0, 1 mM EDTA, 100 mM NaCl, 1.25 ng/ml of the end-labeled complementary nucleic acid (previously rendered single stranded by heating at 95° C. for 5 minutes with 10 mM potassium phosphate buffer/1 mM EDTA and rapid chilling in ice water until added to the reaction mixture), and 711 ng/ml of A1 hnRNP (added last to the experimental mixtures). The reaction mixtures were incubated at 65° C. for 0, 1, 2, 4, 8, 16 and 32 minutes.
The reactions were stopped by diluting 5 μl of the reaction mixture to 20 μl final volume of solution containing 0.1% SDS, 50 μg/ml tRNA, 5% glycerol, and 0.05% bromphenol blue. The reaction products were then extracted with phenol:chloroform (1:1) and the aqueous phase was loaded onto a 10% polyacrylamide gel and electrophoresed for 2 hours at 10 V/cm. The gels were run in a Tris/borate buffer according to Maniatis (1982 at page 454) The gels were then dried and subjected to autoradiography to determine the extent of hybridization. The extent of hybridization was readily determined by comparing the density of single stranded DNA to double stranded DNA in each lane on the gels. Under the given conditions, there is no appreciable annealing detected after 32 minutes without A1 hnRNP. The half-time for annealing under the identical conditions with A1 hnRNP present is less than about 1 minute.
3. The Influence of A1 hnRNP on Acceleration of Nucleic Acid Hybridization Rates Compared to Standard Hybridization Conditions
The reaction conditions were identical to those given in example 2 except reaction mixture A contained 120 mM potassium chloride and 400 ng/ml A1 hnRNP. Reaction mixture B contained 1M NaCl representing standard hybridization conditions. Reaction mixture A was incubated for 5 minutes at 65° C. and mixture B was run for 5 minutes at 68° C. The autoradiographic results indicated that after five minutes, reaction mixture A contained 100% duplexed nucleic acid and no detectable single stranded nucleic acid. Mixture B had no detectable double stranded nucleic acid. The relative acceleration was estimated to be at least 100 fold faster due to A1 hnRNP.
4. The Influence of Temperature Upon the A1 hnRNP Mediated Acceleration of Nucleic Acid Hybridization Rates
The reaction conditions were identical to the reaction conditions provided in example 2 except the mixtures had 4000 ng/ml A1 hnRNP. The reaction mixtures were incubated for 5 minutes at 0°, 23°, 37°, 50° and 65° C. The results demonstrated that acceleration was optimized at the higher temperatures with 100 percent of the label being associated with the double stranded nucleic acid at 65° C. after 5 minutes and about 50% of the label being found in the double stranded nucleic acid after 5 minutes at 37° C.
5. A1 hnRNP Mediated Acceleration of Nucleic Acid Hybridization in the Presence of Excess Heterologous DNA
To establish that A1 hnRNP would accelerate nucleic acid hybridization in the presence of excess heterologous DNA such as would be found in a clinical sample, reactions were run in the presence of M13MP18 single stranded DNA (M13 - ) or M13MP18 single stranded DNA having the same 120 bp target sequences, as described above, cloned into it (M13 + ). The reaction conditions were identical to example 2 except the A1 hnRNP was at 16,000 ng/ml. The temperature was at 65° C. and each reaction was allowed to hybridize for 5 minutes. Reaction mixture A contained no heterologous DNA. Reaction mixture B contained a 1000 fold excess of only M13 - (25 ng). Reaction mixture C contained M13 - (22.5 ng) and M13 + (2.5 ng). Reaction mixture D contained only M13 + (25 ng). After 5 minutes at 65° C., the hybridizations were completed. No significant inhibition of hybridization was detected in mixture B over mixture A. No significant inhibition of hybridization was noted in mixtures C and D wherein it was clearly established that the placement of the target within flanking noncomplementary sequences does not inhibit the ability of A1 hnRNP to effectively accelerate the hybridization rates. Similar results were obtained with boiled genomic DNA replacing the M13MP18 DNA. No strong preference was noted for the annealing of the short nucleic acids (probes) to the target sequences regardless of whether the target was a short fragment or a part of a larger fragment (cloned into a M13 DNA). Moreover, the experimental results were analogous when the hybridizations were run at 37° C. although hybridization rates are slower.
6. The Acceleration Nucleic Acid Hybridization in Solution Using Hexadecyltrimethylammonium Bromide (CTAB)
The reaction conditions were identical to the reaction conditions provided in example 2 except that A1 protein is replaced with CTAB at a final concentration of 0.1%, and the reaction mixtures were incubated at 70° C. for 1 minute. The results demonstrate that renaturation in the presence of CTAB under these conditions allows for renaturation of strands at a rate of approximately 10 7 (liters) (moles nucleotide -1 ) (second -1 ), and is more than 300 fold faster than similar reactions performed in the absence of a secondary binding partner.
7. The Acceleration of Nucleic Acid Hybridization Between Filter-bound DNA and DNA in Solution Using CTAB
Two nanograms of M13+ DNA (see example 5) were spotted onto a 25 mm 2 Nytran®(Schliecher & Schuell, Keene, N.H.) filter and immobilized using ultraviolet radiation from a Stratagene (La Jolla, Calif.) Stratalinker (using UV doses recommended by the manufacturer). The filter was placed on top of three pieces of Whatman 3 MM paper which were pre-wetted with water and the filter was rinsed by adding water to the top of the filter, and removing solution from the underlying Whatman paper with additional dry paper. This procedure allows solution added to the top of the Nytran filter to pass through the filter. Then, fifty microliters of a solution containing 100 picograms of the 124 nt labeled, single-stranded probe DNA, 10 mM potassium phosphate (KPO 4 ) (pH 7.0), 1 mM EDTA, 0.4M NaCl, and 0.1% CTAB was added to the top of the filter, and the solution was allowed to pass through the filter. The filter was then subjected to four successive 10 minute incubations at 60° C. in buffers containing 10 mM KPO 4 , 1 mM EDTA, and the following: 1) 0.4M NaCl, 0.1% CTAB, 2) 4.0M NaCl, 0.1% 3-[(3chloroamidopropyl)dimethylammonio]-2-hydroxy-1-propanesulfonate (CHAPS-a zwitterionic detergent), 3) 4.0M NaCl, 0.1% CHAPS, 4) 0.1M NaCl, 0.1% CHAPS. The filter was subsequently dried and subjected to autoradiography. Under these conditions, signal can be readily detected after two hours. If the M13 DNA does not contain sequence complementary to the probe, significantly less signal is detected.
Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is obvious that certain changes and modifications may be practiced within the scope of the appended claims. | This invention relates to an improvement in promoting the rate of association for high specificity binding pairs used in a variety of industrial, research and medical applications. These pairs include enzyme/substrate, complementary polynucleotide and antibody/antigen combinations. In one specific embodiment, this invention relates to the acceleration of nucleic acid hybridization by heterogeneous nuclear ribonucleoproteins [hnRNPs]. In another specific embodiment, this invention relates to the acceleration of nucleic acid hybridization by a cationic detergent. | 2 |
This application is a divisional of prior application Ser. No. 11/555,349, filed Nov. 1, 2006, now U.S. Pat. No. 7,453,283; which claims priority from Provisional Application No. 60/733,571, filed Nov. 4, 2005.
FIELD OF THE DISCLOSURE
This disclosure relates in general to circuit input and output differential signaling interfaces and in particular to interfaces based on Low Voltage Differential Signaling (LVDS).
BACKGROUND
Today LVDS signaling is being used in a myriad of circuit communication applications, including; (1) system to system communication via cable connections, (2) board to board communication via backplane connections, and (3) IC to IC communication via board or other substrate level connections. The present disclosure anticipates LVDS signaling applications to be extended, beyond these known applications, to include signaling applications between circuits (vender and custom circuits (cores)) embedded within ICs as well. The benefits of LVDS signaling over other (single ended) signaling schemes include; (1) improved signaling noise immunity, (2) lower signaling power consumption, and (3) higher signaling speeds. The drawback of LVDS signaling is that it doubles the number of connections required between a sending circuit and a receiving circuit. The present disclosure, in at least one aspect, eliminates this connection doubling drawback. Conventional LVDS signal communication occurs between an LVDS driver and an LVDS receiver over a pair of signal paths. The pair of signal paths may support bidirectional communication between two driver and receiver pairs, but not simultaneously.
BRIEF SUMMARY
The present disclosure discloses a design of LVDS drivers and receivers such that a pair of LVDS drivers and receivers can simultaneously communicate over a single pair of signal path leads.
A first device comprises a signal source 1 , a signal destination 2 , a LVDS driver, an input circuit, termination resistor, and a resistor in series with each of the differential signal paths. The input circuit receives inputs from the LVDS signal path and from an output from source 1 . The input circuit provides input to destination 2 .
A second device 502 comprises a signal source 2 , a signal destination 1 , an LVDS driver, an input circuit, a termination resistor, and a resistor in series with each of the differential signal paths. The input circuit receives inputs from the LVDS signal path and from an output from source 2 . The input circuit provides input to destination 1 .
A first example input circuit comprises an inverter with its input coupled to the output from the source circuit, a differential receiver with its non-inverting and inverting inputs coupled to the differential signal path, a window comparator with A and B inputs coupled to the differential signal path, and a multiplexer with a first input coupled to the output of the inverter, a second input coupled to the output of the differential receiver, a control input coupled to the output of the window comparator, and an output coupled to the input of the destination circuit.
A second example input circuit comprises an inverter with its input coupled to the output from the source circuit, a window comparator with A and B inputs the differential signal path, and a multiplexer. The multiplexer has a first input coupled to a fixed logic high, a second input coupled to a fixed logic low, a third input coupled to the output of the inverter, a first control input coupled to an output C of the window comparator, a second control input coupled to an output D of the window comparator, and an output coupled to the input to destination circuit.
One example circuit that could be used as window comparator comprises a first comparator with its non-inverting input coupled to the input A, its inverting input coupled to the input B, and its output coupled to the output C. A second comparator has its non-inverting input coupled to the input B, its inverting input coupled to the input A, and its output coupled to output D.
The first comparator is designed such that the voltage on its non-inverting input must be greater than the voltage on its inverting input by an offset voltage (OSV) value (80 millivolts in this example) before the comparator output C will go high. The second comparator is designed such that the voltage on its non-inverting input must be greater than the voltage on its inverting input by an offset voltage (OSV) value (80 millivolts in this example) before the comparator output D will go high. If the voltage difference on the A and B inputs is less than 80 millivolts, comparator outputs C and D go low. While 80 millivolts was used as an example OSV, any desired value of OSV may be used as well.
Another circuit that could be used to realize the window comparator comprises a first comparator with its non-inverting input coupled to the A input and its inverting input coupled to a reference voltage (assumed to be 250 mv in this example), a second comparator with its non-inverting input coupled to the B input and its inverting input coupled to the reference voltage, an OR gate with a first input coupled to the output of the first comparator, a second input coupled to the output of the second comparator, and an output coupled to the C output.
Another circuit that could be used to realize window comparator comprises a first comparator with its non-inverting input coupled to the A input, its inverting input coupled to a reference voltage (assumed to be 250 mv in this example), and an output coupled to the C output, a second comparator with its non-inverting input coupled to the B input, its inverting input coupled to the reference voltage, and an output coupled to the D output.
Each device comprises a deserializer for receiving serial data from the input circuit, data receiving circuitry for inputting parallel data from the deserializer, a serializer for inputting serial data to the driver, and data providing circuitry for inputting parallel data to the serializer. The combination of the data receiving circuitry and deserializer represent one example design for a destination circuit or a source circuit.
One of the devices also comprises clock output circuitry and an LVDS clock driver. The clock output circuitry provides a clock output to driver and outputs control (CTL) signals to operate the providing circuitry, serializer, deserializer, and receiving circuitry. The control (CTL) signals output to the serializer and deserializer from the clock output circuit will operate faster than the control signals to the receiving and providing circuits since they will be controlling the higher speed serial input and output operations occurring over the signal paths. The clock output circuit may employ use of clock and control signal modification circuits such as but not limited to; a phase lock loop, a phase shifter, a frequency divider, or a frequency multiplier. The clock driver is similar to the other drivers and drives LVDS clock outputs from the device on signal paths separate from the other signal paths. LVDS clocking is shown being used to provide high speed clock signals between the devices. If desired, single ended clocking could be used instead of the differential clocking shown, but the clocking frequency would be reduced between the devices. The device outputting the LVDS clock on the clock signal paths is assumed to be a master device.
BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS
FIG. 1A illustrates a prior art LVDS driver communicating a logic one to a prior art LVDS receiver.
FIG. 1B illustrates a prior art LVDS driver communicating a logic zero to a prior art LVDS receiver.
FIG. 2B illustrates a prior art example of a signal source circuit in one device communicating a logic 1 to a signal destination circuit in another device using an LVDS driver and receiver.
FIG. 2B illustrates a prior art example of a signal source circuit in one device communicating a logic 0 to a signal destination circuit in another device using an LVDS driver and receiver.
FIG. 3 illustrates prior art example of signal source and destination circuits of one device communicating with signal source and destination circuits of another device using two pairs of LVDS signal paths.
FIG. 4 illustrates prior art example of signal source and destination circuits of one device communicating with signal source and destination circuits of another device using a one pair of LVDS signal paths.
FIG. 5 illustrates signal source and destination circuits of one device communicating with signal source and destination circuits of another device using one pair of LVDS signal paths according to the present disclosure.
FIG. 6A illustrates a first signal source communicating a logic 1 to a first signal destination simultaneous with a second signal source communicating a logic 1 to a second signal destination using one pair of LVDS signal paths according to the present disclosure.
FIG. 6B illustrates the electrical circuit model of the communication of FIG. 6A .
FIG. 7A illustrates a first signal source communicating a logic 0 to first signal destination simultaneous with a second signal source communicating a logic 0 to a second signal destination using one pair of LVDS signal paths according to the present disclosure.
FIG. 7B illustrates the electrical circuit model of the communication of FIG. 7A .
FIG. 8A illustrates a first signal source communicating a logic 1 to a first signal destination simultaneous with a second signal source communicating a logic 0 to a second signal destination using one pair of LVDS signal paths according to the present disclosure.
FIG. 8B illustrates the electrical circuit model of the communication of FIG. 8A .
FIG. 9A illustrates a first signal source communicating a logic 0 to a first signal destination simultaneous with a second signal source communicating a logic 1 to a second signal destination using one pair of LVDS signal paths according to the present disclosure.
FIG. 9B illustrates the electrical circuit model of the communication of FIG. 9A .
FIG. 10 illustrates use of a single termination resistor in the LVDS signal paths of the present disclosure.
FIG. 11A illustrates a first example of how the input circuit of the present disclosure may be designed.
FIG. 11B illustrates one example of how the window comparator of the input circuit of FIG. 11A may be designed.
FIG. 12A illustrates a second example of how the input circuit of the present disclosure may be designed.
FIG. 12B illustrates one example of how the window comparator of the input circuit of FIG. 12A may be designed.
FIGS. 13A-13D illustrate a second example of how the window comparator of FIG. 11A may be designed.
FIGS. 13E-13H illustrate a second example of how the window comparator of FIG. 12A may be designed.
FIG. 14 illustrates an example of two devices connected together via an LVDS data signal path and an LVDS clock signal path according to the present disclosure.
FIG. 15 illustrates an example of two device connected together via plural LVDS data signal paths and an LVDS clock signal path according to the present disclosure.
FIG. 16 illustrates a first example of a device connected to a debug, trace, or emulation controller via an LVDS data signal path and an LVDS clock signal path according to the present disclosure.
FIG. 17 illustrates a second example of a device connected to a debug, trace, or emulation controller via an LVDS data signal path and an LVDS clock signal path according to the present disclosure.
FIG. 18 illustrates an example of a device connected to an IC or die tester via an LVDS data signal path and an LVDS clock signal path according to the present disclosure.
FIG. 19 illustrates an example of a device connected to an IC or die tester via a plurality of LVDS data signal paths and an LVDS clock signal path according to the present disclosure.
FIG. 20 illustrates an example of a plurality of devices connected to an IC or die tester via LVDS data signal paths and LVDS clock signal paths according to the present disclosure.
DETAILED DESCRIPTION
FIGS. 1A and 1B illustrate the connection between a conventional LVDS driver 100 and receiver 102 . The driver has an input 114 , a non-inverting output 116 and an inverting output 118 . The driver is comprised of transistors, indicated as switches 104 - 110 , that are controlled by the input 114 . The receiver has a non-inverting input 120 , an inverting input 122 , and an output 124 . A first signal path connection 126 is formed between driver output 116 and receiver input 120 . A second signal path connection 128 is formed between driver output 118 and receiver input 122 . A termination resistor 112 is placed across the receiver inputs 120 and 122 .
In FIG. 1A , a logic high is input to the driver. In response, transistors 104 and 106 are turned on and transistors 108 and 110 are turned off. In this arrangement current flows from the driver current source through transistor 104 , termination resistor 112 , and transistor 106 . The direction of the current flow develops a voltage across termination resistor 112 such that the voltage at the receiver input 120 is more positive than the voltage at receiver input 122 . In response to this input voltage, the receiver outputs a logic high on output 124 .
In FIG. 1B , a logic low is input to the driver. In response, transistors 108 and 110 are turned on and transistors 104 and 106 are turned off. In this arrangement current flows from the driver current source through transistor 108 , termination resistor 112 , and transistor 110 . The direction of the current flow develops a voltage across termination resistor 112 such that the voltage at the receiver input 122 is more positive than the voltage at receiver input 120 . In response to this input voltage, the receiver outputs a logic low on output 124 .
FIGS. 1A and 1B are provided to illustrate the conventional operation of current mode LVDS drivers and receivers. Voltage mode LVDS drivers and receivers may also be used, but current mode LVDS drivers and receivers are the most common variety.
FIGS. 2A and 2B illustrate an LVDS connection formed between a first device 200 and a second device 204 . Devices 200 and 204 may be sub-systems in a system, boards in a backplane, ICs on a board or other substrate, or embedded core circuits in an IC. In FIGS. 2A and 2B and all following figures, the devices could represent; (1) a master device coupled to a slave device, (2) a master device coupled to another master device, or (3) a slave device coupled to another slave device.
Example master devices include but are not limited too; a microprocessor, a digital signal processor, a Serdes serializer, a computer, a production or field tester, an emulation controller, and a trace/debug controller.
Example slave devices include but are not limited too; a circuit controlled by a microprocessor, a circuit controlled by a digital signal processor, a Serdes deserializer, a circuit controlled by a computer, a circuit controlled by a tester, a circuit controlled by an emulation controller, and a circuit controlled by a trace/debug controller.
Device 200 comprises a signal source 202 and an LDVS driver 100 . Device 204 comprises a signal destination 206 and an LDVS receiver 102 . The signal source 202 in device 200 may be any type of circuit that operates to output signals to the LVDS driver 100 . The signal destination 204 may be any type of circuit in device 204 that operates to input signals from LVDS receiver 102 . The source and destination circuits could be used to perform a myriad of operations including but not limited to; (1) a functional operation of the device, (2) a test operation of the device, (3) a debug operation of the device, (4) a trace operation of the device, and (5) an emulation operation of the device.
One example signal source circuit could be a Serdes serializer that operates to input parallel data from another circuit within device 200 and to output the data serially to driver 100 . One example signal destination circuit could be a Serdes deserializer that operates to input serial data from receiver 102 and to output the data in parallel to another circuit within device 204 .
FIG. 2A illustrates a logic high being output from source 202 and received by destination 206 . As seen, the driver 100 outputs current from output terminal 116 to output terminal 118 , which develops a voltage across resistor 112 with the polarity being more positive on the receiver input 120 than receiver input 122 . The receiver 102 outputs a logic high to destination 206 in response to the polarity of the voltage across the resister 112 .
FIG. 2B illustrates a logic low being output from source 202 and received by destination 206 . As seen, the driver 100 outputs current from output terminal 118 to output terminal 116 , which develops a voltage across resistor 112 with the polarity being more positive on the receiver input 122 than receiver input 120 . The receiver 102 outputs a logic low to destination 206 in response to the polarity of the voltage across the resister 112 .
In either FIG. 2A or 2 B the termination resistor 112 may exist within device 204 or it may exist external of device 204 . This is true for all following figures.
FIG. 3 illustrates two devices 300 and 302 each having signal source 202 and destination 206 circuits and LVDS driver 100 and receiver 102 circuits. In this example, source 1 202 of device 300 can communicate with destination 1 206 of device 302 and source 2 202 of device 302 can communicate with destination 2 206 of device 300 . The communications can occur simultaneously since separate LVDS signal paths 304 and 306 exist between the devices. Having to use separate LVDS signal paths for simultaneous communication increases the interconnect between devices 300 and 302 .
FIG. 4 illustrates two devices 400 and 402 each having signal source 202 and destination 206 circuits and LVDS driver 402 and receiver 102 circuits. LVDS drivers 402 are similar to LVDS drivers 100 with the exception that the LVDS drivers 402 have an enable input 404 and 406 . The enable input is used to enable or disable the output drive of driver 402 . If enable input 404 is set to enable driver 402 of device 400 and enable input 406 is set to disable driver 402 of device 402 , source 1 202 of device 400 can communicate with destination 1 206 of device 402 . Likewise, if enable input 404 is set to disable driver 402 of device 400 and enable input 406 is set to enable driver 402 of device 402 , source 2 202 of device 402 can communicate with destination 2 206 of device 400 . The communications cannot occur simultaneously but rather must occur at separate times since only one LVDS signal path 410 exists between the devices. Having to communicate at separate times decreases the communication bandwidth between the source and destination circuits of devices 400 and 402 .
As seen in FIG. 4 , the termination resistors 112 of each receiver 102 lie in parallel on the LVDS signal path 410 . This results in a parallel resistance termination (PRT) 412 on the signal path (indicated in dotted line). The value of PRT 412 is equal to the parallel resistance of resistors 112 . For example, if resistors 112 are 100 ohms, a typical value for LVDS termination resistors, PRT will be 50 ohms. Since current mode LVDS drivers 402 output a constant current, a reduction in the signal path termination resistance (i.e. the 50 ohm PRT) will lower differential signaling voltages on the signal path 410 to the receivers 102 . Lowering differential signaling voltages can cause communication problems (i.e. lowers the differential noise margin) between an enabled driver and receiver in the LVDS signaling arrangement of FIG. 4 . Therefore the differential signaling arrangement of FIG. 4 should only be used in applications where noise is low and the signaling path 410 is short.
The present disclosure provides a way to allow simultaneous source to destination communication between devices, like in FIG. 3 , while requiring only a single LVDS signal path interconnect between devices, like in FIG. 4 .
The present disclosure provides a way to maintain appropriate LVDS signaling voltages (and noise margins) on an LVDS signal path where the termination resistance of
FIG. 5 illustrates the LVDS signaling arrangement between devices 500 and 502 according to the present disclosure. Device 500 comprises a signal source 1 202 , a signal destination 2 206 , an LVDS driver 100 , an input circuit 504 , termination resistor 112 , and resistors 506 and 508 . The input circuit 504 receives inputs from LVDS signal path 514 , LVDS signal path 516 , and the output from source 1 202 . The input circuit 514 provides input to destination 2 206 . Resistor R 1 506 is placed in series between the driver output terminal 116 and signal path 514 . Resistor R 2 508 is placed in series between the driver output terminal 118 and signal path 516 .
Device 502 comprises a signal source 2 202 , a signal destination 1 206 , an LVDS driver 100 , an input circuit 504 , termination resistor 112 , and resistors 510 and 512 . The input circuit 504 receives inputs from LVDS signal path 514 , LVDS signal path 516 , and the output from source 2 202 . The input circuit 514 provides input to destination 1 206 . Resistor R 3 510 is placed in series between the driver output terminal 116 and signal path 514 . Resistor R 4 512 is placed in series between the driver output terminal 118 and signal path 516 .
If devices 500 and 502 are boards or other substrates in a system, resistors 506 - 512 could be discrete resistors placed, as shown, in series between the driver outputs 116 and 118 and board/substrate contacts connected to signal paths 514 and 516 .
If devices 500 and 502 are ICs on a board or other substrate, resistors 506 - 512 could be poly or transistor channel resistances placed, as shown, in series between the driver outputs 116 and 118 and IC pads connected to signal paths 514 and 516 .
If devices 500 and 502 are embedded core circuits in an IC, resistors 506 - 512 could be poly or transistor channel resistances placed, as shown, in series between the driver outputs 116 and 118 and core circuit terminals connected to signal paths 514 and 516 .
The LVDS driver and series resistor arrangement could be as shown in FIG. 5 , i.e. the driver and resistors are separate circuits connected together inside the device, or the driver and series resistors could be integrated to form a new driver circuit 518 applicable for use by the present disclosure. The circuitry and detail operation of the input circuits 504 will be described later in regard to FIGS. 11 , 12 , and 13 .
During operation of the devices in FIG. 5 , source 1 202 of device 500 outputs data to driver 100 which transmits differential signals over the signal paths 514 - 516 to input circuit 504 of device 502 to be input to destination 1 206 of device 502 . Simultaneously, source 2 202 of device 502 outputs data to driver 100 which transmits differential signals over the signal paths 514 - 516 to input circuit 504 of device 500 to be input to destination 2 206 of device 500 .
Resistors 506 - 512 should be equal in value or as near equal in value as possible to each other. The value of each resistor 506 - 512 is preferably less than the value of the termination resistor 112 . In the following description of the examples shown in FIGS. 6A-6B , 7 A- 7 B, 8 A- 8 B, 9 A- 9 B, and 10 it will be assumed for simplification that the termination resistors 112 are 100 ohms, resistors 506 - 512 are each 25 ohms, and the drivers 100 are 5 milliamp LVDS drivers.
With 100 ohm termination resistors 112 , the parallel termination resistance (PRT) 412 across the signal paths 514 - 516 , due to the termination resistors 112 , is equal to 50 ohms. While these resistor and current values are used in the description, the present disclosure is not limited to use of only these values. Indeed, other resistance and current values can be used without departing from the spirit and scope of the present disclosure.
In FIG. 6A , it is seen that if source 1 of device 500 and source 2 of device 502 both output a logic high to drivers 100 , input circuit 504 of device 500 will input a logic high to destination 2 of device 500 and input circuit 504 of device 502 will input a logic high to destination 1 of device 502 .
In FIG. 6B , the electrical model of the FIG. 6A signal transfer operation is shown. As seen, driver 100 of device 500 sources current (I 1 ) into signal path 514 from terminal 116 and returns current (I 2 ) from signal path 516 at terminal 118 . Also as seen, driver 100 of device 502 sources current (I 3 ) into signal path 514 from terminal 116 and returns current (I 4 ) from signal path 516 at terminal 118 . The sum of the source currents (I 1 and I 3 ) pass through PRT 412 (the parallel resistance of terminal resistors 112 ) and develop a voltage across PRT with the polarity shown. The voltage developed across PRT is input to the voltage input (Vin) of the input circuits 504 of FIG. 6A . In response to Vin the input circuits 504 output logic highs to destinations 1 and 2 206 .
In FIG. 6B , if the drivers 100 each provide a source current of 5 milliamps, the voltage across each resistor 506 - 512 will be 125 millivolts (i.e. 25 ohms×5 ma) and the voltage across PRT 412 will be 500 millivolts (i.e. 50 ohms×10 ma). A Vin of 500 millivolts with the polarity shown provides a differential LVDS input signal to the input circuits 504 that the input circuits 504 can easily recognize as a logic high. The 500 millivolts differential input signal also provides excellent noise immunity in applications with high noise and long signal paths 514 - 516 .
While a 500 millivolts differential signal was produced in this example using the assumed currents and resistances, other differential signal voltages could be produced using different assumptions on currents and resistances.
In FIG. 7A , it is seen that if source 1 of device 500 and source 2 of device 502 both output a logic low to drivers 100 , input circuit 504 of device 500 will input a logic low to destination 2 of device 500 and input circuit 504 of device 502 will input a logic low to destination 1 of device 502 .
In FIG. 7B , the electrical model of the FIG. 7A signal transfer operation is shown. As seen, driver 100 of device 500 sources current (I 2 ) into signal path 516 from terminal 118 and returns current (I 1 ) from signal path 514 at terminal 116 . Also as seen, driver 100 of device 502 sources current (I 4 ) into signal path 516 from terminal 118 and returns current (I 3 ) from signal path 514 at terminal 116 . The sum of the source currents (I 2 and I 4 ) pass through PRT 412 and develop a voltage across PRT with the polarity shown. The voltage developed across PRT is input to the voltage input (Vin) of the input circuits 504 of FIG. 7A . In response to Vin the input circuits 504 output logic lows to destinations 1 and 2 206 .
In FIG. 7B , if the drivers 100 each provide a source current of 5 milliamps, the voltage across each resistor 506 - 512 will be 125 millivolts (i.e. 25 ohms×5 ma) and the voltage across PRT 412 will be 500 millivolts (i.e. 50 ohms×10 ma). A Vin of 500 millivolts with the polarity shown provides a differential LVDS input signal to the input circuits 504 that the input circuits 504 can easily recognize as a logic low. Again, the 500 millivolts differential input signal provides excellent noise immunity in applications with high noise and long signal paths 514 - 516 .
As in FIGS. 6A-6B , while a 500 millivolts differential signal was produced in the FIG. 7A-7B example using the assumed currents and resistances, other differential signal voltages could be produced using different assumptions on currents and resistances.
In FIG. 8A , it is seen that if source 1 of device 500 outputs a logic high to the driver 100 of device 500 and source 2 of device 502 outputs a logic low to driver 100 of device 502 , input circuit 504 of device 500 will input a logic low to destination 2 of device 500 and input circuit 504 of device 502 will input a logic high to destination 1 of device 502 .
In FIG. 8B , the electrical model of the FIG. 8A signal transfer operation is shown. As seen, driver 100 of device 500 sources current (I 1 ) into signal path 514 from terminal 116 and returns current (I 2 ) from signal path 516 at terminal 118 . Also as seen, driver 100 of device 502 sources current (I 4 ) into signal path 516 from terminal 118 and returns current (I 3 ) from signal path 514 at terminal 116 . In this electrical situation, the current (I 1 ) sourced from driver 100 of device 500 is the current (I 3 ) returned to driver 100 of device 502 , and the current (I 4 ) sourced from driver 100 of device 502 is the current (I 2 ) returned to driver 100 of device 500 .
Since resistors 506 - 512 are assumed to be 25 ohms each and the source currents I 1 and I 4 are assumed to be 5 milliamps each, the voltages present on signal path 514 and signal path 516 are the same or very close to being the same. With the same voltage present on the terminals of PRT 412 , no current, or only a small leakage current, flows through PRT 412 . Thus the voltage drop across PRT (i.e. Vin) that is input to input circuits 504 is extremely small.
In response to the small Vin voltage, the input circuits 504 of devices 500 and 502 are designed to input the opposite logic level that each device 500 and 502 was outputting. For example, since source 1 202 of device 500 in FIG. 8A is outputting a logic high, the input circuit 504 of device 500 will respond to the small Vin voltage by inputting a logic low to destination 2 206 of device 500 . Likewise, since source 2 202 of device 502 in FIG. 8A is outputting a logic low, the input circuit 504 of device 502 will respond to the small Vin voltage by inputting a logic high to destination 1 206 of device 502 .
In FIG. 9A , it is seen that if source 1 of device 500 outputs a logic low to the driver 100 of device 500 and source 2 of device 502 outputs a logic high to driver 100 of device 502 , input circuit 504 of device 500 will input a logic high to destination 2 of device 500 and input circuit 504 of device 502 will input a logic low to destination 1 of device 502 .
In FIG. 9B , the electrical model of the FIG. 9A signal transfer operation is shown. As seen, driver 100 of device 500 sources current (I 2 ) into signal path 516 from terminal 118 and returns current (I 1 ) from signal path 514 at terminal 116 . Also as seen, driver 100 of device 502 sources current (I 3 ) into signal path 514 from terminal 116 and returns current (I 4 ) from signal path 516 at terminal 118 . In this electrical situation, the current (I 2 ) sourced from driver 100 of device 500 is the current (I 4 ) returned to driver 100 of device 502 , and the current (I 3 ) sourced from driver 100 of device 502 is the current (I 1 ) returned to driver 100 of device 500 .
Since resistors 506 - 512 are assumed to be 25 ohms each and the source currents I 2 and I 3 are assumed to be 5 milliamps each, the voltages present on signal path 514 and signal path 516 are the same or very close to being the same. With the same voltage present on the terminals of PRT 412 , no current, or only a small leakage current, flows through PRT 412 . Thus the voltage drop across PRT (i.e. Vin) that is input to input circuits 504 is extremely small.
In response to the small Vin voltage, the input circuits 504 of devices 500 and 502 are designed to input the opposite logic level that each device 500 and 502 was outputting. For example, since source 1 202 of device 500 in FIG. 9A is outputting a logic low, the input circuit 504 of device 500 will respond to the small Vin voltage by inputting a logic high to destination 2 206 of device 500 . Likewise, since source 2 202 of device 502 in FIG. 9A is outputting a logic high, the input circuit 504 of device 502 will respond to the small Vin voltage by inputting a logic low to destination 1 206 of device 502 .
FIG. 10 is provided to indicate that in applications where noise is low and the signal paths are short, a single termination resistor (RT) 1002 may be used between the signal paths instead of the two separate termination resistors 112 previously shown on the input of the input circuits 504 . It is clear that use of a single termination resistor 1002 , of say 100 ohms, will advantageously increase the Vin voltage to the input circuits 504 using the assumed 5 milliamp LVDS drivers 100 . The operation of the present disclosure in the single termination resistor arrangement of FIG. 10 is identical to that previously described in FIGS. 6A-6B through 9 A- 9 B.
As seen from the above descriptions of FIGS. 6A-6B , 7 A- 7 B, 8 A- 8 B, 9 A- 9 B, and 10 , the present disclosure uses a network of resistances (R 1 , R 2 , R 3 , R 4 , and PRT/RT) in an LVDS signal path 514 - 516 in combination with special input circuits 504 to advantageously enable simultaneous differential signal communication between two devices.
FIG. 11A illustrates a first example circuit 1100 that could be used to perform the function of input circuit 504 . Circuit 1100 comprises an inverter 1102 with its input coupled to the output 1120 from source circuit 202 , a differential receiver 102 with its non-inverting input 1108 coupled to signal path 514 and its inverting input 1110 coupled to signal path 516 , a window comparator 1104 with its A input 1112 coupled to signal path 514 and its B input 1114 coupled to signal path 516 , and a multiplexer 1106 with a first input coupled to the output of inverter 1102 , a second input coupled to the output of differential receiver 102 , a control input coupled to the output window comparator 1104 , and an output 1118 coupled to the input to destination circuit 206 .
The function of the window comparator 1104 is to output a logic high on the C output 1116 whenever the voltage on its A input 1112 is greater than the voltage on its B input 1114 plus an offset voltage (OSV) “or” whenever the voltage on its B input 1114 is greater than the voltage on its A input 1112 plus an offset voltage (OSV). Otherwise the window comparator outputs a logic low on the C output 1116 .
The offset voltages (OSV) are set such that if a small differential voltage, as described in FIGS. 8A-8B and 9 A- 9 B, is present between signal paths 514 and 516 , the voltage differential at the A and B inputs of the window comparator 1104 will not be sufficiently large enough to cause the C output of the window comparator to be set to a logic high. Thus in response to small differential voltages, the window comparator 1104 will output a logic low to the control input of multiplexer 1106 , which causes the inverted Out (Out*) signal from the source 202 of a device to be input to the destination 206 of the same device, via multiplexer output 1118 .
On the other hand, if an adequately large differential voltage is present between the signal paths 514 and 516 , the differential voltage at the A and B inputs of the window comparator 1104 will be sufficiently large enough to exceed the offset voltages (OSV) and cause the C output of the window comparator to be set to a logic high. For example, the 500 mv signal of polarity shown in FIGS. 6A-6B will cause output C of the window comparator to be set high. Likewise, the 500 mv signal of polarity shown in FIG. 7A-7B will cause output C of the window comparator to be set high. If output C of the window comparator is high, multiplexer 1106 will output the output of receiver 102 to the destination 206 via multiplexer output 1118 . For example, receiver 102 will output a logic high to destination 206 , via multiplexer 1106 , in response to receiving the 500 mv signal of polarity shown in FIGS. 6A-6B . Further, receiver 102 will output a logic low to destination 206 , via multiplexer 1106 , in response to receiving the 500 mv signal of polarity shown in FIGS. 7A-7B .
In summary, the input circuit 1100 of FIG. 11A outputs the inverted output of the source 202 of a device to the destination 206 of the same device if the differential voltage on signal paths 514 and 516 is small and within a voltage window established by offset voltage (OSV) settings. The input circuit 1100 of FIG. 11A outputs the output of the receiver 102 to the destination 206 of the device if the differential voltage on signal paths 514 and 516 is large and outside the voltage window established by the offset voltage (OSV) settings.
FIG. 11B illustrates one example circuit 1124 that could be used as window comparator 1104 of FIG. 11B . The circuit 1124 comprises a first comparator 1126 with its non-inverting input 1132 coupled to input A 1112 and its inverting input 1134 coupled to input B 1114 , a second comparator 1128 with its non-inverting input 1136 coupled to input B 1114 and its inverting input 1138 coupled to input A 1112 , an OR gate 1130 with a first input coupled to the output of comparator 1126 , a second input coupled to the output of comparator 1128 , and an output coupled to output C 1116 .
Comparator 1126 is designed such that the voltage on its non-inverting input 1132 must be greater than the voltage on its inverting input 1134 by an offset voltage (OSV) value (assumed to be 80 millivolts in this example) before the comparator output will go high. Comparator 1128 is designed such that the voltage on its non-inverting input 1136 must be greater than the voltage on its inverting input 1138 by an offset voltage (OSV) value (assumed to be 80 millivolts in this example) before the comparator output will go high. If the voltage difference on the A and B inputs is less than 80 millivolts, output C goes low. If the voltage difference on the A and B inputs is greater than 80 millivolts, output C goes high. While 80 millivolts was used as an example OSV, any desired value of OSV may be used as well.
FIG. 12A illustrates a second example circuit 1200 that could be used to perform the function of input circuit 504 . Circuit 1200 comprises an inverter 1202 with its input coupled to the output 1216 from source circuit 202 , a window comparator 1204 with its A input 1208 coupled to signal path 514 and its B input 1210 coupled to signal path 516 , and a multiplexer 1206 with a first input coupled to a fixed logic high, a second input coupled to a fixed logic low, a third input coupled to the output of inverter 1202 , a first control input coupled to output C 1212 of window comparator 1204 , a second control input coupled to output D 1214 of window comparator 1204 , and an output 1218 coupled to the input to destination circuit 206 .
The functions of the window comparator 1204 are:
(1) to output a logic high on output C and a logic low on output D whenever the voltage on its A input 1208 is greater than the voltage on its B input 1210 plus an offset voltage (OSV) “and” the voltage on its B input 1210 is less than the voltage on its A input plus an offset voltage (OSV), (2) to output a logic low on output C and a logic high on output D whenever the voltage on its A input 1208 is less than the voltage on its B input 1210 plus an offset voltage (OSV) “and” the voltage on its B input 1210 is greater than the voltage on its A input plus an offset voltage (OSV), (3) to output a logic low on output C and output D whenever the voltage on its A input 1208 is less than the voltage on its B input 1210 plus an offset voltage (OSV) “and” the voltage on its B input 1210 is less than the voltage on its A input plus an offset voltage (OSV).
The offset voltages (OSV) are set such that if a small differential voltage, as described in FIGS. 8A-8B and 9 A- 9 B, is present between signal paths 514 and 516 , the voltage differential at the A and B inputs of the window comparator 1204 will not be sufficiently large enough to cause both the C and D outputs of the window comparator to be set high. Thus in response to small differential voltages, the window comparator 1204 will output logic lows to the control inputs of multiplexer 1206 , which causes the inverted Out (Out*) signal from the source 202 of a device to be input to the destination 206 of the same device, via multiplexer output 1206 .
On the other hand, if an adequately large differential voltage is present between the signal paths 514 and 516 , the differential voltage at the A and B inputs of the window comparator 1104 will be sufficiently large enough to exceed the offset voltages (OSV) and cause either the C or D output of the window comparator to be set high. For example, the 500 mv signal of polarity shown in FIGS. 6A-6B will cause output C to be set high and output D to be set low. Likewise, the 500 mv signal of polarity shown in FIG. 7A-7B will cause output D to be set high and output C to be set low.
If output C is high and output D is low, multiplexer 1206 will output the fixed logic high input to destination 206 via multiplexer output 1218 . If output C is low and output D is high, multiplexer 1206 will output the fixed logic low input to destination 206 . And as mentioned, if both output C and D are low, multiplexer 1206 will output the inverted output (Out*) of the source 202 of a device to the destination 206 of the same device.
In summary, the input circuit 1200 of FIG. 12A outputs the inverted output of the source 202 of a device to the destination 206 of the same device if the differential voltage on signal paths 514 and 516 is small and within a voltage window established by offset voltage (OSV) settings. The input circuit 1200 of FIG. 12A outputs the fixed logic high to the destination 206 of the device if the differential voltage on signal paths 514 and 516 is such that the voltage on input A is sufficiently larger that the voltage on input B plus the offset voltage (OSV). The input circuit 1200 of FIG. 12A outputs the fixed logic low to the destination 206 of the device if the differential voltage on signal paths 514 and 516 is such that the voltage on input B is sufficiently larger that the voltage on input A plus the offset voltage (OSV).
FIG. 12B illustrates one example circuit 1220 that could be used as window comparator 1204 of FIG. 12B . The circuit 1220 comprises a first comparator 1222 with its non-inverting input 1226 coupled to input A 1208 , its inverting input 1228 coupled to input B 1210 , and its output coupled to output C 1212 , and a second comparator 1224 with its non-inverting input 1230 coupled to input B 1210 , its inverting input 1232 coupled to input A 1208 , and its output coupled to output D 1214 .
Comparator 1222 is designed such that the voltage on its non-inverting input 1226 must be greater than the voltage on its inverting input 1228 by an offset voltage (OSV) value (80 millivolts in this example) before the comparator output C will go high. Comparator 1224 is designed such that the voltage on its non-inverting input 1230 must be greater than the voltage on its inverting input 1232 by an offset voltage (OSV) value (80 millivolts in this example) before the comparator output D will go high. If the voltage difference on the A and B inputs is less than 80 millivolts, comparator outputs C and D go low. While 80 millivolts was used as an example OSV, any desired value of OSV may be used as well.
FIGS. 13A-13D show another circuit 1300 that could be used to realize window comparator 1104 of FIG. 11A . Circuit 1300 comprises a first comparator 1302 with its non-inverting input coupled to the A input and its inverting input coupled to a reference voltage (assumed to be 250 mv in the FIG. 13A-13D examples), a second comparator 1304 with its non-inverting input coupled to the B input and its inverting input coupled to the reference voltage, an OR gate 1306 with a first input coupled to the output of comparator 1302 , a second input coupled to the output of comparator 1304 , and an output coupled to the C output. To simply the description, circuit 1300 will be shown used in the signaling arrangements previously described in FIGS. 6B , 7 B, 8 B, and 9 B, and with the previously assumed resistance and current values stated for said Figures.
FIG. 13A illustrates that in the previously described signaling arrangement of FIG. 6B , the voltage (625 mv) on the A input of circuit 1300 , coupled to signal path 514 , will be greater than the reference voltage (250 mv) and the voltage (125 mv) on the B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1302 will output a logic high to OR gate 1306 and comparator 1304 will output a logic low to OR gate 1306 . In response, the OR gate will output a logic high on the output C, causing multiplexer 1106 of FIG. 11A to output the output of receiver 102 to destination 206 as previously described.
FIG. 13B illustrates that in the previously described signaling arrangement of FIG. 7B , the voltage (125 mv) on the A input of circuit 1300 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and the voltage (625 mv) on the B input, coupled to signal path 516 , will be greater than the reference voltage (250 mv). Thus comparator 1302 will output a logic low to OR gate 1306 and comparator 1304 will output a logic high to OR gate 1306 . In response, the OR gate will output a logic high on the output C, causing multiplexer 1106 of FIG. 11A to output the output of receiver 102 to destination 206 as previously described.
FIG. 13C illustrates that in the previously described signaling arrangement of FIG. 8B , the voltage (125 mv) on the A input of circuit 1300 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and the voltage (125 mv) on the B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1302 will output a logic low to OR gate 1306 and comparator 1304 will output a logic low to OR gate 1306 . In response, the OR gate will output a logic low on the output C, causing multiplexer 1106 of FIG. 11A to output the output (Out*) of inverter 1102 to destination 206 as previously described.
FIG. 13D illustrates that in the previously described signaling arrangement of FIG. 9B , the voltage (125 mv) on the A input of circuit 1300 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and voltage (125 mv) on the B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1302 will output a logic low to OR gate 1306 and comparator 1304 will output a logic low to OR gate 1306 . In response, the OR gate will output a logic low on the output C, causing multiplexer 1106 of FIG. 11A to output the output (Out*) of inverter 1102 to destination 206 as previously described.
FIGS. 13E-13H depicts another circuit 1308 that could be used to realize window comparator 1204 of FIG. 12A . Circuit 1308 comprises a first comparator 1310 with its non-inverting input coupled to the A input, its inverting input coupled to a reference voltage (assumed to be 250 mv in the FIG. 13E-13H examples), and an output coupled to the C output, a second comparator 1312 with its non-inverting input coupled to the B input, its inverting input coupled to the reference voltage, and an output coupled to the D output. To simply the description, circuit 1308 will be shown used in the signaling arrangements previously described in FIGS. 6B , 7 B, 8 B, and 9 B, and with the previously assumed resistance and current values stated for said Figures.
FIG. 13E illustrates that in the previously described signaling arrangement of FIG. 6B , the voltage (625 mv) on the A input of circuit 1308 , coupled to signal path 514 , will be greater than the reference voltage (250 mv) and the voltage (125 mv) the on B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1310 will output a logic high on the C output and comparator 1312 will output a logic low on the D output. In response to C being high and D being low, multiplexer 1206 of FIG. 12A will output the fixed logic high input to destination 206 as previously described.
FIG. 13F illustrates that in the previously described signaling arrangement of FIG. 7B , the voltage (125 mv) on the A input of circuit 1308 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and the voltage (625 mv) the on B input, coupled to signal path 516 , will be greater than the reference voltage (250 mv). Thus comparator 1310 will output a logic low on the C output and comparator 1312 will output a logic high on the D output. In response to C being low and D being high, multiplexer 1206 of FIG. 12A will output the fixed logic low input to destination 206 as previously described.
FIG. 13G illustrates that in the previously described signaling arrangement of FIG. 8B , the voltage (125 mv) on the A input of circuit 1308 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and the voltage (125 mv) the on B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1310 will output a logic low on the C output and comparator 1312 will output a logic low on the D output. In response to C being low and D being low, multiplexer 1206 of FIG. 12A will output the output (Out*) of inverter 1202 to destination 206 as previously described.
FIG. 13H illustrates that in the previously described signaling arrangement of FIG. 9B , the voltage (125 mv) on the A input of circuit 1308 , coupled to signal path 514 , will be less than the reference voltage (250 mv) and the voltage (125 mv) the on B input, coupled to signal path 516 , will be less than the reference voltage (250 mv). Thus comparator 1310 will output a logic low on the C output and comparator 1312 will output a logic low on the D output. In response to C being low and D being low, multiplexer 1206 of FIG. 12A will output the output (Out*) of inverter 1202 to destination 206 as previously described.
While FIGS. 11A-11B , 12 A- 12 B, and 13 A-G have shown various examples of how to design input circuits 504 for use by the present disclosure, it is anticipated that other ways of designing input circuits 504 will be conceived by those skilled in the art. Thus the present disclosure is not limited to only using the example input circuit designs shown and described herein.
FIG. 14 illustrates two devices 1400 and 1402 coupled together using an LVDS signal path 514 - 516 for transferring data signals and an LVDS signal path 1424 - 1426 for transferring clock signals. The devices communicate data simultaneously between each other using input circuit 504 , driver 100 , and signaling path resistor network as previously described. The data being communicated could be of any data type, including but not limited to; functional data, test data, debug data, trace data, and emulation data.
Device 1400 comprises a deserializer 1404 for inputting serial data from input circuit 504 , data receiving circuitry 1406 for inputting parallel data from the deserializer 1404 , a serializer 1408 for inputting serial data to driver 100 , and data providing circuitry 1410 for inputting parallel data to serializer 1408 . The combination of the data receiving circuitry 1406 and deserializer 1404 represent one example design for a destination circuit 206 . The combination of the data providing circuitry 1410 and serializer 1408 represent one example design for a source circuit 202 . Device 1400 also comprises clock output circuitry 1412 and an LVDS clock driver 1428 . The clock output circuitry 1412 provides a clock output to driver 1428 and outputs control (CTL) signals to operate the providing circuitry 1410 , serializer 1408 , deserializer 1404 , and receiving circuitry 1406 . The control (CTL) signals output to the serializer and deserializer from the clock output circuit will operate faster than the control signals to the receiving and providing circuits since they will be controlling the higher speed serial input and output operations occurring over signal paths 514 and 516 . The clock output circuit 1412 may employ use of clock and control signal modification circuits such as but not limited to; a phase lock loop, a phase shifter, a frequency divider, or a frequency multiplier. Driver 1428 is similar to driver 100 and drives LVDS clock outputs from device 1400 on signal paths 1424 and 1426 . LVDS clocking is shown being used to provide high speed clock signals from device 1400 to device 1402 . If desired, single ended clocking could be used instead of the differential clocking shown, but the clocking frequency would be reduced between device 1400 and 1402 . Device 1400 is assumed to be a master device since it outputs the LVDS clock on signal paths 1424 - 1426 .
Device 1402 comprises a deserializer 1418 for inputting serial data from input circuit 504 , data receiving circuitry 1420 for inputting parallel data from the deserializer 1418 , a serializer 1414 for inputting serial data to driver 100 , and data providing circuitry 1416 for inputting parallel data to serializer 1414 . As in device 1400 , the combination of the data receiving circuitry 1420 and deserializer 1418 represent one example design for a destination circuit 206 , and the combination of the data providing circuitry 1416 and serializer 1414 represent one example design for a source circuit 202 . Device 1402 also comprises clock input circuitry 1422 and an LVDS clock receiver 1430 . The clock input circuitry 1422 receives the clock output from receiver 1430 and outputs control (CTL) to operate the providing circuitry 1416 , serializer 1414 , deserializer 1418 , and receiving circuitry 1420 . The control (CTL) signals output to the serializer and deserializer from the clock input circuit will operate faster than the control signals to the receiving and providing circuits since they will be controlling the higher speed serial input and output operations occurring over signal paths 514 and 516 . The clock input circuit 1422 may employ use of clock and control signal modification circuits such as but not limited to; a phase lock loop, a phase shifter, a frequency divider, or a frequency multiplier. Receiver 1430 is similar to receiver 102 and inputs the LVDS clock outputs from device 1400 on signal paths 1424 and 1426 . Device 1402 is assumed to be a slave device since it inputs the LVDS clock on signal paths 1424 - 1426 .
During operation data is transmitted from the providing circuitry 1410 and serializer 1408 of device 1400 to the deserializer 1418 and receiving circuitry 1420 of device 1402 . Simultaneous with data transmitted from device 1400 to device 1402 , data is transmitted from the providing circuitry 1416 and serializer 1414 of device 1402 to the deserializer 1404 and receiving circuitry 1406 of device 1400 . The simultaneous data transfers between devices 1400 and 1402 are controlled by clock output circuitry 1412 of device 1400 and the clock input circuitry 1422 of device 1402 . As mentioned, internal to device 1400 , clock output circuitry 1412 provides the control (CTL) inputs to operate the providing 1410 , serializer 1408 , deserializer 1404 , and receiving 1406 circuits. External to the device, Clock output circuitry 1412 provides the LVDS clock input to device 1402 . Internal to device 1402 , and in response to the LVDS clock input from device 1400 , the clock input circuitry 1422 provides the control (CTL) inputs to operate the providing 1416 , serializer 1414 , deserializer 1418 , and receiving 1420 circuits.
FIG. 15 is provided to indicate that a plurality of the providing ( 1410 , 1416 ), serializer ( 1408 , 1414 ), deserializer ( 1404 , 1418 ), and receiver ( 1406 , 1420 ) circuit arrangements 1504 - 1510 of FIG. 14 could exist in devices 1500 and 1502 . Each arrangement 1504 - 1506 in device 1500 operable, in response to the clock output circuitry 1412 to communicate data simultaneously with an associated arrangement 1508 - 1510 in device 1502 via an input circuit 504 , driver 100 , resistors, and LVDS signal path 1512 / 1514 .
FIG. 16 illustrates a device 1600 coupled to a debug, trace, or emulation controller 1610 via an LVDS signal path 1606 and LVDS clock path 1608 according to the present disclosure. The debug, trace, or emulation controller 1610 is similar in design to the master device 1400 of FIG. 14 with the exception that its specific function is to control a debug, trace, or emulation operation in device 1600 via the data and clock signal paths 1606 and 1608 . Device 1600 is similar to the slave device 1402 of FIG. 14 with the exception that the providing circuit 1416 of FIG. 14 is indicated to be a memory or other circuit 1602 that needs to be controlled by device 1610 to output data during a debug, trace, or emulation operation, and the receiving circuit 1420 of FIG. 14 is indicated as being a memory or other circuit 1604 that needs to be controlled by device 1610 to input data during a debug, trace, or emulation operation.
Using the LVDS signaling approach of the present disclosure, much higher debug, trace, and/or emulation communication can occur between master device 1610 and slave device 1600 , as opposed to other approaches used in the industry today. For example, it is well known to use the IEEE 1149.1 standard interface (i.e. JTAG) for debug, trace, and/or emulation operations. However, standard JTAG communication rates between a master and slave device is limited to around 50-100 MHz. Since the present disclosure uses LVDS signaling, the communication rates between a master 1610 and slave 1600 during debug, trace, and/or emulation operations can be greater than 400 MHz. Indeed, using the LVDS signaling approach of the present disclosure, communication for debug, trace, and/or emulation operations may well extend into the gigahertz range. Device 1600 can be extended, as shown in device 1502 of FIG. 15 , to include a plurality of LVDS signal paths and associated driver 100 , input circuits 504 , serializer 1414 and deserializer 1418 such that high speed communication to greater number of debug, trace, and/or emulation circuits 1602 and 1604 is possible.
FIG. 17 is provided to indicate that a slave device 1700 may use a shift register 1702 during debug, trace, and/or emulation operations instead of a separate serializer 1414 (i.e. a serial in/parallel out circuit) and a separate deserializer 1418 (i.e. a parallel in/serial out circuit) if desired. In operation the shift register 1702 loads parallel debug, trace, and/or emulation data from circuit 1602 and shifts the data out to driver 100 as debug, trace, and/or emulation data is shifted in from input circuit 504 to be loaded in parallel to debug, trace, and/or emulation circuit 1604 .
FIG. 18 illustrates a device 1800 coupled to an IC or Die tester 1810 via an LVDS signal path 1806 and LVDS clock path 1808 according to the present disclosure. The tester 1810 is similar in design to the master device 1400 of FIG. 14 with the exception that its specific function is to control a test operation in device 1800 via the data and clock signal paths 1806 and 1808 . Device 1800 is similar to the slave device 1402 of FIG. 14 with the exception that a scan path 1802 is coupled between the output of the input circuit 504 and the input of driver 100 , and a circuit under test 1804 is shown coupled to the scan path 1802 to be the receiving 1420 and providing 1416 circuits during test operations. Device 1800 can be a packaged IC, an unpackaged IC die, or a die on wafer. The circuit under test 1804 is typically, but not limited to being, combinational logic. The serial data input to scan path 1802 from input circuit 504 is stimulus test data to be applied in parallel 1812 to the inputs of circuit under test 1804 . The serial data output from scan path 1802 to driver 100 is response test data loaded in parallel 1814 to the scan register from the circuit under test outputs. Scan testing is well known. What is new is performing scan testing using the LVDS signaling approach of the present disclosure.
Using the LVDS signaling approach of the present disclosure, much higher test input and output communication can occur between master device 1810 and slave device 1800 , as opposed to other approaches used in the industry today. For example, known scan interface used in the industry today (IEEE standards 1149.1 and 1500) are limited to scan test communication rates/frequencies of around 50-100 MHz. Since the present disclosure uses LVDS signaling, the communication rates between a master 1810 and slave 1800 during scan testing can be greater than 400 MHz. Indeed, using the LVDS signaling approach of the present disclosure, communication for scan test operations may well extend into the gigahertz range.
FIG. 19 illustrates a device 1900 coupled to an IC or Die tester 1912 via a plurality of LVDS signal paths 1906 - 1908 and an LVDS clock path 1910 according to the present disclosure. Each LVDS signal path 1906 - 1908 is coupled to an arrangement 1902 - 1904 of drivers 100 , input circuits 504 , scan paths 1802 , and circuits under test 1804 . The tester 11912 is similar to tester 1810 with the exception that it can communicate to the device 1900 over the plurality of LVDS signal paths 1906 - 1908 , instead of the single LVDS signal path of FIG. 18 . By increasing the number of LVDS signal paths and arrangements 1902 - 1904 a larger number of circuits 1804 can be tested in parallel, which decreases test time of device 1900 .
FIG. 20 illustrates either a plurality or ICs 2018 - 2030 in a fixture 2000 or a plurality of die 2018 - 2030 on a wafer 2000 interfaced to a plural IC or die tester 2002 via LVDS data and clock signal paths 2004 - 2016 . If the IC or die 2018 - 2030 are the type shown in FIG. 18 , there will be one LVDS data signal path pair and one LVDS clock signal path pair between the tester 2002 and each IC or die 2018 - 2030 . If the IC or die 2018 - 2030 are the type shown in FIG. 19 , there will be one LVDS clock signal path pair and a plurality of LVDS data signal path pairs (indicated by increased line width) between the tester 2002 and each IC or die 2018 . FIG. 20 illustrates how a plurality of ICs 2018 - 2030 in a fixture 2000 or a plurality of die 2018 - 2030 on a wafer 2000 may be scan tested in parallel (i.e. at the same time) using the LVDS signaling approach of the present disclosure.
While FIGS. 18-20 have illustrated the LVDS signaling approach of the present disclosure for testing ICs or die using a scan test approach, other test approaches may be interfaced to the LVDS signaling approach of the present disclosure as well. Other test approaches that may be interfaced to the LVDS signaling interface of the present disclosure may include but are not limited to, (1) a test approach based on IEEE standard 1149.1, (2) a test approach based on IEEE standard 1149.4, (3) a test approach based on IEEE standard 1149.6, (4) a test approach based on IEEE standard 1500, (5) a test approach based on built in self test, and (6) a test approach based on functional testing.
Although the present disclosure has been described in detail, it should be understood that various changes, substitutions and alterations may be made without departing from the spirit and scope of the disclosure as defined by the appended claims. | First and second devices may simultaneously communicate bidirectionally with each other using only a single pair of LVDS signal paths. Each device includes an input circuit and a differential output driver connected to the single pair of LVDS signal paths. An input to the input circuit is also connected to the input of the driver. The input circuit may also receive an offset voltage. In response to its inputs, the input circuit in each device can use comparators, gates and a multiplexer to determine the logic state being transmitted over the pair of LVDS signal paths from the other device. This advantageously reduces the number of required interconnects between the first and second devices by one half. | 7 |
BACKGROUND OF THE INVENTION
The present invention concerns an electric linear actuator of the type comprising an electric motor, a tubular body comprising a piston and connecting means between the motor and the piston (commonly known as a jack).
Electric linear actuators used until now have been driven by an electric motor disposed outside the body of the linear actuator rotating a screwthreaded rod through a gear, the rod driving the piston of the linear actuator.
Linear actuators of the above kind are bulky, permeable because they are not sealed and fragile because the force is transmitted to the piston by a screwthreaded rod. There is a risk of the rod buckling when the linear actuator is operating in compression with a long travel.
Sealing against dust, inclement weather and moisture is difficult because the linear actuator is in two parts.
SUMMARY OF THE INVENTION
An aim of the invention is therefore to propose an electric linear actuator in which the above drawbacks are eliminated.
In accordance with the invention, the piston of the linear actuator is a tube mounted to slide in the body, the motor is housed inside the piston and the aforementioned connecting means cooperate with the inside wall of the body to move the piston in thrust or in traction.
Placing the motor inside a tubular piston of the linear actuator means that the linear actuator can be made in one compact unit of considerably reduced overall size.
In a preferred embodiment of the invention, the body and the piston being cylindrical, the motor is a gear motor one end of which is attached to the piston and an output shaft of which is adapted to rotate a nut provided with an external screwthread meshing with a complementary internal screwthread on the inside wall of the body.
In this way the electric gear motor transmits its rotation to the nut at the end of the gearbox and bearing directly on the screwthread in the linear actuator body.
A structure of the above kind therefore eliminates the screwthreaded rod for transmitting the force of the linear actuator and the associated risk of the rod buckling, because it is the tubular body of the linear actuator that receives the reaction forces.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will become apparent during the following description given with reference to the accompanying drawings which show two embodiments by way of non-limiting example.
FIG. 1 is a perspective view of a first embodiment of the electric linear actuator of the invention, shown with the piston deployed.
FIG. 2 is a view of the linear actuator from FIG. 1 in axial longitudinal section with the piston retracted inside the body.
FIG. 3 is a view in cross-section taken along the line 3--3 in FIG. 2, the gear motor having been removed.
FIG. 4 is a partial view in elevation to a larger scale on the line 4--4 in FIG. 3.
FIG. 5 is a part-sectional view to a larger scale of a detail from FIG. 2.
FIG. 6 is a view similar to FIG. 2 of a second embodiment of the electric linear actuator of the invention.
FIG. 7 is a half-sectional view taken along the line 7 in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electric linear actuator shown in the drawings comprises an electric gear motor 1 disposed inside a tubular piston 2 coaxial with the longitudinal axis XX of the piston. The cylindrical piston 2 slides along the axis XX inside a tubular body 3.
The piston 2 is closed at one end by a transverse flange 4 to which an end face of the gear motor 1 is fixed. Its opposite end is closed by a stopper 5 through which passes a bore 6 to receive an attachment (not shown).
One end 8 of the output shaft of the gear motor 1 passes axially through the flange 4 and is attached by a key 8a to a nut 9 which can therefore be rotated by the shaft end 8. The nut 9 includes a central sleeve 9a surrounding the shaft 8 and has an external screwthread 11 meshing with a complementary internal screwthread 12 on the inside wall of the cylindrical body 3 over a distance corresponding to the intended travel of the piston 2. The screwthreads 11 and 12 have rectangular cross-sections, preferably square cross-sections (FIG. 5), with a large clearance j between the conjugate teeth 11a, 12a, preferably a clearance in the order of approximately 0.5 mm. The nut 9 is fixed to a disk 13 with a central opening concentric with a central cylindrical flange 4a of the flange 4 surrounding the sleeve 9a. The nut 9 is attached to the disk 13 by longitudinal screws 14, one of which can be seen in FIG. 2.
Needle roller bearings 15 are disposed between the disk 13, on the one hand, and on the flange 4 and a ring-nut 16 screwed onto the end of the flange 4a, on the other hand. The linear actuator is also provided with means for preventing the cylindrical body 2 rotating relative to the piston 3. In the example shown these means comprise a tubular stud 17 fixed to the piston 2, extending transversely through the body 3 and able to slide in a longitudinal slot 18 in the body 3. The stud 17 is fixed to the piston 2 by screws 17a and delimits an opening 10 through which an electric wire 22 passes.
A sheath 21 for protecting the electric wire or cable 30 supplying power to the gear motor 1 is housed in a longitudinal opening 19 in the wall of the body 3 facing the slot 18. The wire 30 extends inside a coil spring 22 forming a U-shape loop 22a in the sheath 21. The sheath, which preferably has a U-shape profile as seen in FIG. 3, extends longitudinally from one end to the other of the body 3 to which it is fixed by appropriate means, not shown. An obturator 23 closes the sheath 21 at the level of the flange 28. The sheath 21 receives part of the length of the electric wire 30. The two runs of the loop 22a lie in a plane substantially perpendicular to that of FIG. 2, as can be seen in FIG. 3. Accordingly, the wire 30 extends first from the end of the gear motor 1 facing towards the stopper 5 and then between the gear motor 1 and the piston 2 as far as the tubular stud 17, passing through the opening 10 in the stud into the sheath 21. The wire 30 passes through an opening 25 in the sheath 21 and a cable gland 24 for connection to the mains electrical power supply.
On the side of the piston 2 opposite the stopper 5 the body 3 is closed off by a cover 26 fixed to the body 3 by screws 27, for example. The linear actuator is also provided with sealing means. In the example shown, the end of the body 3 contiguous to the end stopper 5 is provided with a ring 28 fixed to the body 3 by screws 20. A seal 29 is disposed between the ring 28, the end of the body 3 and the piston 2, the seal 29 being housed in a corresponding groove in the body 3. A second ring 31 for sealing and guiding the piston 2 is accommodated in the inside wall of the body 3 to complete the seal with the piston 2.
Another seal 32 is advantageously disposed between the cover 26 and the body 3, being housed in a groove formed in the end of the body 3.
The electric linear actuator that has just been described operates in the following manner.
The wire 30 being connected to the mains electrical power supply and the gear motor 1 and the piston 2 being assumed to be in their extreme bottom positions shown in FIG. 2, when the gear motor 1 is operated in the appropriate direction its shaft end 8 rotates the nut 9. The screwthread 11 slides with clearance in the screwthread 12, applying a longitudinal thrust to the disk 13. This thrust is transmitted to the flange 4 via the needle roller bearings 15 and thus to the tubular piston 2, which begins to deploy from the body 3 with its attachment 7 and the gear motor 1 inside it.
During the movement in translation of the piston 2 the wire 30 is entrained so that the loop formed by the wire in the sheath 21 is progressively paid out via the transverse stud 17, continuing to be protected by the spring sheath 22, as the stud 17 moves in translation in the slot 18.
When the gear motor 1 is operated in the opposite direction the nut 9 turns in the opposite direction and therefore retracts the piston 2 inside the body 3, the loop formed by the wire 30 in the sheath 21 being progressively closed up and the stud 17 returning to its initial position. The spiral winding of the wire 30, shown only in FIG. 4, imparts some elasticity to it which facilitates the reforming of the loop 22a during the return travel of the piston 2.
The nut 9 is advantageously made from a hard material such as steel and the tubular body 3 is formed from a composite material of high mechanical strength with a very low coefficient of friction. A pair of materials of the above kind assures satisfactory sliding between the nut 9 and the body 3. Furthermore, to avoid all risk of the nut 9 jamming in the body 3, it is necessary for the large clearance j previously mentioned to be provided between the teeth 11a and 12a (FIG. 5). A small clearance (for example 0.1 mm) could lead to the nut 9 jamming in the body 3 and thereby jamming the linear actuator.
Moreover, the fact that the screwthread 11 and the screwthread 12 have teeth 11a, 12a of rectangular, preferably square, cross-section has the advantage that in the event of failure of the electrical power supply the nut 9 remains in its position within the body 3 and does not drop back; the piston 2 therefore remains in its previous position.
Housing the gear motor 1 inside the piston 2 considerably reduces the overall size of the linear actuator as a whole and makes it particularly compact. Moreover, as already indicated, this transformation eliminates the screwthreaded rod of conventional electric linear actuators and therefore the risk of this rod buckling.
The fact that the motor 1 is inside the piston 2 also makes the linear actuator particularly quiet in operation.
The second embodiment of the linear actuator, shown in FIGS. 6 and 7, includes a cylindrical external jacket 33 around the body 3. On the body a longitudinal flat 34 delimits with the corresponding sector of the jacket 33 a gap 35 which contains the spring 22 through which the electric wire 30 passes to form a loop as in the previous embodiment.
The spring 22 passes through a stud 36 fixed to the piston 2 and able to slide in a longitudinal opening 37 in the body 3. A screw 38 mounted on the stud 36 attaches the spring 22 to it and a second screw 39 passing through the jacket 33 holds the spring 22 in place in the space 35.
At its upper end (assuming the linear actuator is vertical) the linear actuator has a ring 41 for closing off the annular gap between the jacket 33 and the stopper 5. A seal is provided by a seal 42 disposed between the body 3 and the ring 41.
At the bottom end of the linear actuator a flange 43 is fixed to the sleeve 33 and to the cover 26 by screws 44, a seal 45 being disposed between the cover 26 and the flange 43.
The electric wire 30 passes through a cable gland 46 near the flange 43, which seals it.
The external jacket 33, which is preferably made from a composite material, advantageously soundproofs the linear actuator.
The linear actuator can easily be miniaturised to suit appropriate applications and there is no limit as to its possible applications. | An electric actuator including a gear motor (1), a tubular body (3) containing a piston (2), and a connection of the motor to the piston. The piston consists of a tube (2) slidable within the body. The motor (1) is housed within the piston and secured to an end flange (4) thereof, and the output shaft (8) of the motor rotates a plug (9) provided with a screw thread (11) meshed with a complementary thread (12) on the inner wall of the body (3). As the gear motor (1) is housed within the tubular piston (2), the actuator is exceptionally compact and quiet, and the problem of the buckling of threaded rods in conventional actuators is avoided since said rods have been replaced by a tubular piston (2). Furthermore, this arrangement makes the actuator easy to seal. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a liquid phase growth method of a silicon crystal, a method for producing a solar cell, and a liquid phase growth apparatus and, more particularly, to a liquid phase growth method that permits continuous growth and volume production.
[0003] 2. Related Background Art
[0004] Liquid phase growth methods have the advantage of the capability of obtaining crystals with high quality close to stoichiometric compositions because of crystal growth from the quasi-equilibrium state and are used in production of LEDs (light-emitting diodes), laser diodes, and so on, as techniques already established in such compound semiconductors as GaAs. Recently, attempt has been made to utilize the liquid phase growth of Si in order to obtain a thick film (for example, Japanese Patent Application Laid-Open No. 58-89874) and application to solar cells is also under research.
[0005] In the conventional liquid phase growth methods, in general, a solution containing a substance for growth as a solute is cooled into a supersaturated state to deposit the excess solute (the substance for growth) on a substrate. On that occasion, it is necessary to preliminarily dissolve the solute into a solvent until saturated, prior to depositing (or growing) the solute on the substrate. Ordinary methods for dissolving the solute into the solvent include one for preliminarily mixing the solute in an amount enough to saturate at a temperature during the dissolution into the solvent and heating the solvent, and one for heating a large amount of a base material of the solute (over a saturation amount) in contact with the solvent and keeping it at the dissolving temperature to saturate. In the former case, a newly weighed amount of the solute is charged into the solvent or the old solvent is replaced by another solvent in which the solute was preliminarily dissolved, after every completion of growth. In the latter case, the base material of the solute is taken into and out of the solvent before or after the growth and the base material will be used up at last to cause some harm in taking it into or out of the solvent or result in an insufficient dissolved amount. Therefore, the old base material needs to be replaced by a new base material. In either case, time loss occurs, because the apparatus is stopped for supplying the raw material when used up or because the growth is suspended. Therefore, the methods according to the conventional techniques had the problem in terms of volume productivity.
[0006] The present invention has been accomplished as a consequence of intensive and extensive research by the inventors in order to solve the problem in the conventional techniques as discussed above and an object of the present invention is, therefore, to provide a liquid phase growth method that is simple and easy and that has high volume productivity.
SUMMARY OF THE INVENTION
[0007] Therefore, the present invention provides a liquid phase growth method of a silicon crystal comprising a step of injecting a source gas comprising at least silicon atoms into a solvent to decompose the source gas and, simultaneously therewith, dissolving the silicon atoms into the solvent, thereby supplying the silicon atoms into the solvent, and a step of dipping or contacting a substrate into or with the solvent, thereby growing a silicon crystal on the substrate.
[0008] Further, the present invention provides a method of producing a solar cell comprising at least a step of forming a silicon layer by liquid phase growth, the method comprising a step of injecting a source gas comprising at least silicon atoms into a solvent to decompose the source gas and, simultaneously therewith, dissolving the silicon atoms into the solvent, thereby supplying the silicon atoms into the solvent, and a step of dipping or contacting a substrate into or with the solvent, thereby growing a silicon crystal on the substrate to form said silicon layer.
[0009] Moreover, the present invention provides a liquid phase growth apparatus of a silicon crystal comprising means for holding a solvent in which silicon atoms are dissolved, and means for dipping or contacting a substrate into or with the solvent, the apparatus further comprising means for injecting a source gas comprising at least silicon atoms into the solvent.
[0010] Further, the present invention provides a liquid phase growth apparatus of a silicon crystal comprising a solvent reservoir for holding a solvent in which silicon atoms are dissolved, a source gas inlet pipe having an opening portion in the solvent held in the solvent reservoir, a wafer cassette for holding a substrate, the wafer cassette being arranged to be freely taken into or out of the solvent held in the solvent reservoir, and a heater.
[0011] Moreover, the present invention provides a liquid phase growth apparatus of a silicon crystal comprising a solvent reservoir and a growth vessel each for holding a solvent in which silicon atoms are dissolved, a pipe for circulating the solvent between the solvent reservoir and the growth vessel, a source gas inlet pipe having an opening portion in the solvent held in the solvent reservoir, a wafer cassette for holding a substrate, the wafer cassette being arranged to be freely taken into or out of the solvent held in the growth vessel, and a heater.
[0012] In addition, the present invention provides a liquid phase growth apparatus of a silicon crystal comprising a solvent reservoir for holding a solvent in which silicon atoms are dissolved, a pipe both ends of which are connected to the solvent reservoir and which has an aperture portion except for the both ends, the pipe being provided for circulating the solvent, a source gas inlet pipe having an opening portion in the solvent held in the solvent reservoir, a holding member for holding a substrate so that the substrate is in contact with the solvent at the aperture portion, and a heater.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic sectional view showing an example of the liquid phase growth apparatus according to the present invention;
[0014] [0014]FIG. 2 is a schematic sectional view showing an apparatus that permits the dissolution of silicon and liquid phase growth to be carried out simultaneously, as an example of the liquid phase growth apparatus according to the present invention;
[0015] [0015]FIG. 3 is a schematic sectional view showing an apparatus having a mechanical agitating means, as an example of the liquid phase growth apparatus according to the present invention; and
[0016] [0016]FIG. 4 is a schematic sectional view showing an apparatus in which a substrate is in contact with a solvent at an aperture portion, as an example of the liquid phase growth apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] An example of the liquid phase growth apparatus, which is used in the liquid phase growth method of the present invention, is illustrated in FIG. 1. In FIG. 1 reference numeral 101 designates a wafer cassette, 102 substrates (wafers), 103 a solvent reservoir (crucible), 104 a solvent (melt), 105 a reaction product gas, 106 a source gas inlet pipe, 107 a reactor tube, and 108 an electric furnace (heater).
[0018] Further, numeral 109 denotes gas outlet holes provided in the source gas inlet pipe, 110 a gate valve, and 111 an exhaust port.
[0019] The liquid phase growth method and liquid phase growth apparatus of the present invention will be described referring to FIG. 1. As illustrated in FIG. 1, the solvent reservoir (crucible) 103 made of carbon is filled with the solvent comprised of a metal (hereinafter referred to as metal solvent) 104 and the supply pipe 106 for introduction of the source gas is set along the side wall and bottom surface of the crucible 103 . The wafer cassette 101 carrying the wafers 102 is located above the crucible 103 and is moved vertically to dip the wafers 102 in the metal solvent 104 or lift the wafers 102 up out of the metal solvent 104 , thereby performing growth start operation/growth end operation. The wafer cassette 101 is equipped with a rotating mechanism and the wafer cassette 101 is rotated thereby during growth to uniform thicknesses of a grown film in each wafer surface and thicknesses of grown films among the wafers. The crucible 103 , source gas inlet pipe 106 , and wafer cassette 101 are housed in the reactor tube 107 and are heated by the electric furnace 108 located outside the reactor 107 .
[0020] Specific procedures of the liquid phase growth method of the present invention will be described. First, the unsaturated metal solvent, or the metal solvent 104 after an end of growth is heated to a predetermined temperature (a little higher than the growth temperature) and kept thereat before stabilized. Then the source gas, for example SiH 4 , as a supply source of Si is allowed to flow in the source gas inlet pipe 106 , so that the source gas (SiH 4 ) is injected into the metal solvent through the gas outlet holes 109 opening in the surface of the inlet pipe placed at the bottom surface of the crucible, whereupon the source gas (SiH 4 ) comes into contact with the metal solvent. When SiH 4 is used as the source gas, the SiH 4 coming into contact with the metal solvent soon reacts to be decomposed into Si atoms and H 2 molecules. The Si atoms are dissolved into the metal solvent. At this time, the H 2 molecules thus evolved agitate the metal solvent to promote the dissolution of the Si atoms into the solvent. It can also be contemplated that the solvent is positively agitated with an agitating mechanism (not illustrated) provided separately. After the SiH 4 gas is injected into the metal solvent for a certain time, the flow of the SiH 4 gas is stopped and the metal solvent is slowly cooled by controlling the electric furnace 108 . When the temperature of the metal solvent reaches the growth start temperature, the wafer cassette 101 is moved down to dip the wafers 102 into the metal solvent 104 . Preferably, the wafer cassette 101 is rotated at the rate of several rpm during the growth so as to uniform the thicknesses of grown films. After a lapse of a predetermined growth time, the wafer cassette 101 is moved up out of the metal solvent 104 , thereby terminating the growth. Since in the present embodiment the wafers 102 are mounted at a fixed inclination in the wafer cassette 101 , there remains little metal solvent 104 on the wafer surfaces when they are drawn up out of the metal solvent 104 . There are, however, some cases where a small amount of the metal solvent remains at contact portions (support portions) between the wafers 102 and the wafer cassette 101 . In such cases, the wafer cassette is rotated at the rotational speed of several ten or higher rpm, whereby the remaining metal solvent can be thrown off. Subsequently, the wafer cassette is lifted up into a preliminary chamber (not illustrated) separated from the reactor, in which the wafers are exchanged. Then the above steps are repeated, thereby continuously performing liquid phase growth operations.
[0021] The feature of the present invention is that the source material can be continuously supplied into the solvent with the source gas kept in contact with the metal solvent, which eliminates the time loss due to the exchange of the base material as the solute and the like in the conventional methods, thereby enhancing the volume productivity.
[0022] In the present invention, as the material for the solvent reservoir for storing the metal solvent and as the material for the wafer cassette for supporting the wafers, there is preferably used high-purity carbon or high-purity quartz or the like. Similarly, high-purity carbon or high-purity quartz or the like is also used as a preferred material for the source gas inlet pipe used in the present invention, and high-purity quartz is used as a preferred material for the reactor tube. As the source gas used herein, there are preferably included silanes such as SiH 4 , Si 2 H 6 , . . . , Si n H 2n+2 (n: natural number) and silane halides such as SiH 2 Cl 2 , SiHCl 3 , SiCl 4 , SiH 2 F 2 , and Si 2 F 6 .
[0023] Further, it is preferable to add hydrogen (H 2 ) to the source gas, as a carrier gas or for the purpose of obtaining a reducing atmosphere to promote the crystal growth. The ratio of amounts of the source gas and hydrogen is properly determined depending upon the forming method, type of the source gas, and forming conditions, and the ratio is preferably not less than 1:1000 nor more than 100:1 (based on the ratio of flow rates of introduced gases) and more preferably not less than 1:100 nor more than 10:1.
[0024] As the solvent used in the present invention, a solvent comprised of a metal such as, In, Sn, Bi, Ga, Sb, or the like is preferred. Epitaxial growth is effected by contacting the source gas into the solvent to dissolve the Si atoms thereinto and thereafter slowly cooling the solvent or by providing a temperature difference in the solvent while supplying the Si atoms from the source gas into the solvent.
[0025] The temperature and pressure in the liquid phase growth method employed in the present invention differ depending upon the forming method, the type of the source material (gas) used, etc., but the temperature of the solvent is desirably controlled in the range of not less than 600° C. nor more than 1050° C. when silicon is grown using the solvent of Sn or In, for example. The appropriate pressure is generally in the range of 10 −2 Torr to 760 Torr and more preferably in the range of 10 −1 Torr to 760 Torr.
[0026] When the conductivity type (the p-type/n-type) of Si needs to be controlled, a gas containing a dopant such as P, B, etc. may be introduced into the solvent as the occasion demands. Further, a solar cell element can be formed by growing a silicon crystal by use of indium as a solvent without addition of a particular dopant to form a silicon layer and thereafter forming an n-type layer, for example, by a method for diffusing the dopant into a part of the silicon layer by such a method as thermal diffusion, ion implantation, or the like.
[0027] The growth of a desired crystal by the method of the present invention will be described in more detail using examples, but it should be noted that the present invention is by no means intended to be limited to these examples.
EXAMPLE 1
[0028] In the present example an epitaxial layer of Si was grown using the liquid phase growth apparatus of the structure illustrated in FIG. 1. The solvent was In and the source gas was SiH 4 . While the wafer cassette 101 carrying five 5″ Si wafers 102 was kept on standby in a preliminary chamber (not illustrated), the solvent reservoir 103 storing the In solvent 104 was heated by the heater 108 to keep the temperature of the solvent at the constant temperature of 960° C. Here, 5″ means that the diameter of the wafers is 5 inches. Then the wafer cassette 101 kept on standby in the preliminary chamber was guided into the reactor 107 while opening the gate valve 110 and it was held immediately above the solvent reservoir 103 . The gate valve was kept open thereafter. The source gas SiH 4 , together with H 2 gas (in the ratio of gas flow rates: SiH 4 /H 2 =1:1), was injected through the source gas inlet pipe 106 into the In solvent 104 and these gases were kept flowing for 30 minutes. After the flow of the gases was stopped, the heater 108 was controlled so as to start slowly cooling the solvent in the reactor tube 107 at a rate of −1° C./min. When the temperature of the In solvent 104 reached 950° C., the wafer cassette 101 was moved down into the In solvent 104 while being rotated at the rotational speed of 10 rpm. When the wafer cassette 101 was completely dipped in the In solvent 104 , the down movement was stopped and the wafer cassette was held at that position. Then the liquid phase growth was carried on for 60 minutes while rotating the wafer cassette. After that, the wafer cassette 101 was drawn up out of the In solvent 104 and was temporarily stopped immediately above the solvent reservoir 103 . Then the rotational speed was increased up to 120 rpm to throw the partly remaining In off the wafer cassette, and the liquid phase growth was completed.
[0029] Cross sections of the wafers thus obtained were observed with a scanning electron microscope and a transmission electron microscope and it was verified that the epitaxial silicon layers thus grown had a thickness of about 15 μm and also had good crystallinity.
EXAMPLE 2
[0030] In the present example an epitaxial layer of Si was grown by using the liquid phase growth apparatus of the structure illustrated in FIG. 3 and using a mechanical agitating means (agitating mechanism) in combination to dissolve the solute in the solvent. The solvent was In and the source gas was Si 2 H 6 . While the agitating mechanism 312 was kept on standby in a preliminary chamber (not illustrated), the solvent reservoir 303 storing the In solvent 304 was heated by a heater 308 to keep the temperature of the solvent at the constant temperature of 960° C. Then the agitating mechanism 312 kept on standby in the preliminary chamber was guided into the reactor tube 307 while opening the gate valve 310 and was held immediately above the solvent reservoir 303 . The gate valve was kept opening thereafter. The source gas Si 2 H 6 , together with H 2 gas (in the ratio of gas flow rates: Si 2 H 6 /H 2 =1:1), was injected through the source gas inlet pipe 306 into the In solvent 304 and the agitating mechanism 312 was moved down into the In solvent 304 while being rotated at a rotational speed of 20 rpm. When the blades 313 of the agitating mechanism were adequately dipped in the In solvent, the down motion was stopped and the agitating mechanism was held at that position. Then the gases were allowed to flow for 30 minutes while agitating the solvent. After the end of the flow of the gases, the agitating mechanism 312 was drawn up to the preliminary chamber and then the wafer cassette 301 carrying five 5″ Si wafers 302 this time was guided from a preliminary chamber (not illustrated) into the reactor tube 307 to be held immediately above the solvent reservoir 303 for 10 minutes. Then the heater 308 was controlled to start slowly cooling the solvent in the reactor tube 307 at a rate of −1.5° C./min. When the temperature of the In solvent 304 reached 950° C., the wafer cassette 301 was moved down into the In solvent 304 while being rotated at a rotational speed of 10 rpm. When the wafer cassette 301 was completely dipped in the In solvent 304 , the down motion was stopped and the wafer cassette 301 was held at that position. Then the liquid phase growth was carried on for 45 minutes while rotating the wafer cassette. After that, the wafer cassette 301 was lifted up out of the In solvent 304 and was temporarily stopped immediately above the solvent reservoir 303 . Then the rotational speed was increased up to 120 rpm, thereby throwing the partly remaining In off the wafer cassette, and the liquid phase growth operation was ended. In FIG. 3 numeral 305 represents the reaction product gas, 309 the gas outlet holes, and 311 the exhaust port.
[0031] Cross sections of the wafers thus obtained were observed with a scanning electron microscope and a transmission electron microscope and it was verified that the epitaxial silicon layers thus grown had a thickness of about 15 μm and also had good crystallinity.
EXAMPLE 3
[0032] In the present example an epitaxial layer of Si was grown using the apparatus illustrated in FIG. 2.
[0033] The solvent was Sn and the source gas was SiH 2 Cl 2 . The apparatus illustrated in FIG. 2 has a solvent reservoir 214 made of quartz, a growth vessel 203 in which a wafer cassette 201 carrying substrates (wafers) 202 are dipped, and quartz pipes 209 a, 209 b, 210 routed out of one side surface of the solvent reservoir 214 , through the growth cell 203 , and back to another side surface of the solvent reservoir 214 , inside an electric furnace 207 . The pipes 209 a, 209 b serve as heat exchangers. The solvent reservoir 214 and heat exchanger 209 b are further surrounded by a heater block 208 so as to be able to control the temperature independently. Numeral 211 designates a rotor for circulation, 212 a gate valve, 206 a source gas inlet pipe, and 213 an exhaust port. Further, numeral 204 is the solvent and 205 the reaction product gas.
[0034] The solvent 204 of Sn sufficiently purified in a hydrogen atmosphere was charged into the solvent reservoir 214 , growth vessel 203 , and quartz pipes 209 a, 209 b, 210 and the temperature inside the electric furnace 207 was kept at the constant temperature of 950° C. The temperature of the solvent reservoir 214 was set 10° C. higher by the heater block 208 than the temperature inside the electric furnace 207 and outside the heater block 208 and the solvent 204 was circulated by the rotor 211 .
[0035] After a lapse of a sufficient time, the wafer cassette 201 carrying five 5″ p + ( 100 ) Si wafers 202 (wafers doped with a relatively large amount of a p-type dopant and having the principal plane of the crystal plane orientation of ( 100 )) was guided from a preliminary chamber (not illustrated) into the growth vessel 203 while opening the gate valve 212 to be held immediately above the Sn solvent 204 . The source gas SiH 2 Cl 2 , together with H 2 gas (in the ratio of gas flow rates: SiH 2 Cl 2 /H 2 =1:5), was injected through the source gas inlet pipe 206 into the Sn solvent 204 in the solvent reservoir 214 and the gases were kept flowing. After a lapse of 30 minutes, the wafer cassette 201 was moved down into the Sn solvent 204 in the growth vessel 203 while being rotated at a rotational speed of 10 rpm. When the wafer cassette 201 was completely dipped in the Sn solvent 204 , the down movement was stopped and the wafer cassette was held at that position. Then the liquid phase growth was carried on for 60 minutes while rotating the wafer cassette. Then the wafer cassette 201 was drawn up out of the Sn solvent 204 and was temporarily stopped immediately above the Sn solvent 204 . The rotational speed was increased up to 150 rpm to throw the partly remaining Sn off the wafer cassette 201 , and the liquid phase growth operation was terminated.
[0036] Cross sections of the wafers thus obtained were observed with a scanning electron microscope and a transmission electron microscope and it was verified that the epitaxial silicon layers thus grown had a thickness of about 20 μm and also had good crystallinity.
EXAMPLE 4
[0037] In the present example an Si layer was grown on polycrystalline Si substrates by use of the apparatus illustrated in FIG. 4. The solvent was In+Ga (Ga content: 0.1 atomic %) and the source gas was SiH 4 . The substrates were each obtained by processing polycrystalline Si formed by the casting method into the width 40 mm, the length 250 mm, and the thickness 0.6 mm, polishing the surface thereof, and thereafter cleaning it.
[0038] The apparatus illustrated in FIG. 4 has a solvent reservoir 414 of carbon, and flat pipes 409 a, 409 b, 410 made of carbon in an electric furnace 407 , the pipes 409 a, 409 b, 410 being routed so as to leave one side surface of the solvent reservoir 414 , contact a slider 402 on which a plurality of substrates 401 are placed, at an aperture portion 403 , and then return to another side surface of the solvent reservoir 414 . The pipes 409 a, 409 b serve as heat exchangers. The solvent reservoir 414 and heat exchanger 409 b are further surrounded by heater block 408 , so that the temperature can be controlled independently. Numeral 411 denotes the rotor for circulation, 406 the source gas inlet pipe, and 413 the exhaust port. Further, numeral 404 represents the solvent and 405 the reaction product gas.
[0039] The solvent 404 of In+Ga sufficiently purified in a hydrogen atmosphere was charged into the solvent reservoir 414 and flat pipes 409 a, 409 b, 410 , and the position of the slider 402 was preliminarily adjusted so that the Si substrates 401 were not in contact with the solvent 404 at the aperture portion 403 of the flat pipe. In that state, the temperature inside the electric furnace 407 was kept at the constant temperature of 950° C. and, at the same time, the temperature of the solvent reservoir 414 was set 10° C. higher by the heater block 408 than the temperature inside the electric furnace 407 and outside the heater block 408 . The solvent 404 was circulated by the rotor 411 . At this time the length of the aperture portion 403 was 100 mm and the circulation rate of the solvent 404 was 40 mm/min. In the present example three Si substrates were placed on the slider.
[0040] Then the source gas SiH 4 , together with the H 2 gas (in the ratio of gas flow rates: SiH 4 /H 2 =1:1), was injected through the source gas inlet pipe 406 into the In+Ga solvent 404 and the gases were kept flowing. After a lapse of 30 minutes, the slider 402 was conveyed at a conveyance speed of 20 mm/min and the liquid phase growth was effected at the aperture portion 403 with the polycrystalline Si substrate 401 being kept in contact with the In+Ga solvent 404 . After all the polycrystalline Si substrates 402 have passed the aperture portion 403 , the conveyance of the slider 401 was stopped and the liquid phase growth was ended.
[0041] Cross sections of the wafers were observed with a scanning electron microscope and a transmission electron microscope, with the result that the Si layers thus grown had a thickness of about 20 μm. The orientations of the Si layers thus grown were inspected by the ECP (Electron Channeling Pattern) method and it was found that they inherited the crystal orientations of the respective grains of the base polycrystalline Si substrates. The present example verified that the crystalline Si layer was able to be grown continuously while conveying the substrates as described above.
[0042] Example 4 described above showed the example using the substrates placed on the slider, but it is also possible, for instance, to bring a web-like substrate having an Si layer attached on a surface thereof into contact with a solvent and convey the substrate in one direction by the roll-to-roll method, thus continuously growing the Si layer.
EXAMPLE 5
[0043] In the present example n + /p-type thin-film single-crystal solar cells were made using the liquid phase growth method of the present invention. First, by using the apparatus illustrated in FIG. 1, an epitaxial Si layer was grown on a 500 μm-thick p + Si wafer (ρ=0.01 Ω·cm) in the similar fashion to Example 1. The epitaxial growth was carried out in the same manner as in Example 1 except that the wafer was different and that the slow cooling rate of the In solvent 104 was −2° C./min.
[0044] The thickness of the Si layer thus grown was evaluated by a step gage or the like to be about 30 μm. Then thermal diffusion of P was effected at a temperature of 900° C. on the surface of the Si layer thus grown with a diffusion source of POCl 3 , thereby forming the n + layer. The junction depth obtained was about 0.5 μm. The dead layer in the surface of the n + layer thus formed was wet-oxidized and thereafter removed by etching, thereby obtaining the junction depth of about 0.2 μm with a moderate surface concentration.
[0045] In the last place, by EB (Electron Beam) evaporation, a collector electrode (Ti/Pd/Ag (40 nm/20 nm/1 μm)) and an ITO transparent conductive film (82 nm) were deposited on the n + layer and a back surface electrode (Al (1 μm)) was deposited on the back surface of the substrate, thereby forming the solar cell.
[0046] The I-V characteristics of the thin-film single-crystal Si solar cells thus obtained were measured under irradiation with light of AM 1.5 (100 mW/cm 2 ). In the cell area of 6 cm 2 , typically an open-circuit voltage 0.6 V, a short-circuit current 33 mA/cm 2 , a fill factor 0.77, and an energy conversion efficiency 15.2% were obtained.
[0047] The present invention has enabled to continuously perform the crystal growth without interruption for supply of a source material in the liquid phase growth method of a silicon crystal. The present invention is suitably applicable to volume production methods of devices required to have some thickness, particularly, to those of solar cells. | Provided are a liquid phase growth method of silicon crystal comprising a step of injecting a source gas containing at least silicon atoms into a solvent to decompose the source gas and, simultaneously therewith, dissolving the silicon atoms into the solvent, thereby supplying the silicon atoms into the solvent, and a step of dipping or contacting a substrate into or with the solvent, thereby growing a silicon crystal on the substrate; and a method of producing a solar cell utilizing the aforementioned method. Also provided is a liquid phase growth apparatus of a silicon crystal comprising means for holding a solvent in which silicon atoms are dissolved, and means for dipping or contacting a substrate into or with the solvent, the apparatus further comprising means for injecting a source gas containing at least silicon atoms into the solvent. These provide a liquid phase growth method of a silicon crystal and a production method of a solar cell each having high volume productivity and permitting continuous growth. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/388,138 (Atty. Dock. No. TUBE/0002), filed Feb. 18, 2009, and U.S. patent application Ser. No. 12/388,166 (Atty. Dock. No. TUBE/0003), filed Feb. 18, 2009, both of which are herein incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to a method of drying a tubular string to prevent bedwrap corrosion.
[0004] 2. Description of the Related Art
[0005] Coiled tubing (CT) strings are utilized to perform a variety of functions inside oil, gas and water wells, such as pumping fluid through the CT string from the ground surface at the wellhead to the bottom of the well. Once the desired work on the well is completed, the CT string is removed from the well and recoiled onto a spool. Due to the nature of the CT string often being many thousands of feet in length and a small interior diameter, residual fluid & contaminants remain in the CT string in very small quantities.
[0006] Conventional methods of drying CT strings include blowing large volumes of high pressure nitrogen through the CT string in an attempt to force any remaining corrosive liquids out of the coil of tubing. Even when these methods are used in combination with conventional pipeline pigs, small amounts of corrosive fluids & residue remain in the coil and continue to corrode or rot the tubing at the 6 o'clock position while the coil is in storage or waiting for the next use. There is currently no known method by which all corrosive fluids & residue can be removed from such CT strings.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention generally relate to a method of drying a tubular string to prevent bedwrap corrosion. In one embodiment, a method of drying a tubular string includes deploying a first bypass pig in the tubular string. The method further includes injecting propellant behind the first bypass pig, thereby driving the first bypass pig through the tubular string. A portion of the propellant bypasses the first bypass pig, thereby drying an inner surface of the tubular string.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0009] FIG. 1 illustrates pigtrain deployed in a coiled tubing string, according to one embodiment of the present invention. FIG. 1A is an enlargement of a portion of FIG. 1 .
[0010] FIG. 2A is a longitudinal cross-section of a trail bypass pig of the pigtrain. FIG. 2B is a radial cross-section of the trail bypass pig.
[0011] FIG. 3A is a longitudinal cross-section of a lead bypass pig of the pigtrain. FIG. 3B is an end view of the lead bypass pig.
DETAILED DESCRIPTION
[0012] FIG. 1 illustrates a pigtrain 1 deployed in a coiled tubing (CT) string 50 , according to one embodiment of the present invention. FIG. 1A is an enlargement of a portion of FIG. 1 . Alternatively, the pigtrain 1 may be deployed in other tubular strings, such as a pipeline or reeled pipe. The pigtrain 1 may include one or more lead pigs 300 and a trail pig 200 . The lead and trail designations and inlet and outlet designations may be arbitrary as the pigtrain 1 may be bidirectional and/or the inlet 55 i and outlet 55 o may be reversed. As discussed below, the pigtrain 1 may be deployed to dry the CT string 50 . As discussed above, the CT string 50 may have residual liquid from being deployed into a wellbore. Alternatively, it may be desirable to dry the CT string 50 after manufacture on the manufacturer's production reel or after use in a pipeline.
[0013] In preparing the CT string 50 for deployment of the pigtrain 1 , an inlet 55 i and outlet 55 o of the CT string 50 may be located at or near ground level to allow for easier access. A clamp (not shown) may be secured to each of the inlet 55 i and outlet 55 o . Each clamp may have a flange or threaded coupling to receive corresponding flanges or threaded couplings of a pig launcher (not shown) and a pig receiver (not shown). The launcher and receiver designations may be arbitrary as the pigtrain 1 may be bidirectional. Each of the launcher and receiver may include a pipe and a bumper. The pipe may include a propellant port and a door at an end thereof for insertion or removal of the pig. The pipe may have an increased diameter relative to the CT string 50 and each of the launcher and receiver may further include a reducer connecting the pipe to the CT string 50 to facilitate ease of insertion or removal of the pigtrain 1 .
[0014] The lead 300 and trail 200 pigs may be loaded into the launcher followed by the bumper. The door of the launcher may be closed and a propellant supply hose may be connected to the propellant port. The receiver bumper may also be loaded into the receiver pipe, the door closed, and a vent hose connected to the propellant supply.
[0015] Propellant P may be injected into the launcher to drive the pigtrain 1 through the CT string 50 . The propellant P may be a fluid, such as compressed gas, such as dry air or nitrogen. When the pigtrain 1 reaches the receiver connected to the outlet 55 o, the lead pig 300 may be stopped by the receiver bumper. At this point, the propellant P may be sampled and the moisture content measured and compared to a predetermined level to determine if the CT string 50 is dry after one pass or if the pigtrain 1 needs be driven back through the CT string 50 until the pigtrain 1 reaches the launcher bumper. This back and forth movement of the pigtrain 1 may be repeated until an inner surface of the coiled tubing 50 is sufficiently clean and/or dry. Alternatively, the pigtrain 1 may be transported back to the launcher and redeployed using the launcher. Alternatively, the pigtrain may be inverted and deployed using the receiver.
[0016] Alternatively, the bumpers may be omitted. Alternatively, the pig launcher and receiver as illustrated in FIGS. 1 and 9 - 11 of U.S. Pat. No. 5,230,842, which is herein incorporated by reference in its entirety, may be used to launch and receive the pigtrain 1 . Alternatively, the pigtrain 1 may be deployed into the CT string 50 without using a launcher and receiver. Additionally, a second pigtrain (not shown) may be deployed in series with the pigtrain 1 . The second pigtrain may include a lead bypass pig and a trail bypass pig. The second pigtrain may be deployed adjacent to the pigtrain 1 such that the second pigtrain utilizes the lead or trail pig of the pigtrain 1 as one of its members. Alternatively, the second pigtrain may be deployed a distance from the pigtrain 1 such that a cushion of propellant exists between the pigtrains. In this alternative, the second pigtrain may have its own lead pig and trail pig.
[0017] Alternatively, the pigtrain 1 may be used as part of a multi-cycle regimen for treating, such as cleaning and/or coating, the CT string 50 . One regimen may include a first cycle including deploying a pigtrain discussed and illustrated in the '166 application (incorporated above), back and forth through the CT string 50 one or more times with a first working fluid, such as detergent, and a second cycle with a different second working fluid, such as water or neutralizer.
[0018] The '166 pigtrain may include a lead pig, a bypass pig, and a trail pig. The bypass pig may be either of the pigs 200 , 300 and the lead and trail pigs may be similar to either of the pigs 200 , 300 except for omission of the bypass. When the '166 pigtrain is initially deployed in the CT string 50 from the launcher, the bypass pig may be in a first position closer to the lead pig than the trail pig, such as proximate to or abutting the lead pig. As the '166 pigtrain proceeds through the CT string 50 , a portion of the working fluid may flow through the bypasses, thereby forcing the bypass pig to gradually move from the first position to a second position closer to the trail pig than the lead pig, such as proximate to or abutting the trail pig, relative to the movement of the '166 pigtrain. The relative movement of the bypass pig may agitate the working fluid and/or liquid residue as the '166 pigtrain proceeds through the CT string 50 , thereby facilitating the removal of debris from the inner surface of the CT string.
[0019] The regimen may be a multi-cycle cleaning regimen for cleaning and then sealing the CT string 50 with a pressurized gage pressure or zero gage pressure atmosphere, such as dry air or nitrogen, inside the coiled tubing 50 to prevent corrosion thereof during storage. The '166 pigtrain may be deployed with the detergent, such as a surfactant or basic solution, for a degreasing cycle. The cycle may be repeated until a white-metal or near white-metal finish, such as NACE number one or two, is achieved. The '166 pigtrain may then be deployed with water for a rinse cycle. The '166 pigtrain may then be deployed with the corrosion inhibitor. The pigtrain 1 may then be deployed with dry air or nitrogen propellant for a drying cycle. A squeegee pig, such as a foam pig, may be deployed with nitrogen or dry air propellant for a blanket cycle. The ends 55 i, o may be sealed with the blanket inside the coiled tubing 50 at positive or zero gage pressure and the CT string 50 placed in storage.
[0020] Alternatively, the regimen may be a multi-cycle interior coating regimen for the CT string 50 . The regimen may include deployment of the '166 pigtrain with the detergent, such as a surfactant or basic solution, for a degreasing cycle. The '166pigtrain may then be deployed with water for a rinse cycle. The '166 pigtrain may then be deployed with another detergent, such as an acidic solution, for descaling. The cycle may be performed until a white-metal or near white-metal finish, such as NACE number one or two, is achieved. The '166 pigtrain may then be deployed with the neutralizer. The pigtrain 1 may then be deployed with dry air or nitrogen propellant for a drying cycle. The '166 pigtrain may then be deployed with the corrosion inhibitor. The coating (not shown) may be applied by injecting liquid coating material, such as a polymer (i.e., epoxy, polyurethane, or polytetrafluoroethylene) between two extruder pigs (not shown) of a pigtrain and propelling the pigtrain using dry air or nitrogen through the CT string 50 .
[0021] Suitable pipeline extruder pigs are illustrated in FIGS. 3-6 of the '842 patent. The pipeline extruder pigs may be modified for use in coiled tubing or reeled pipe by omitting the intermediate disc members and shortening the base portion of the leading pig and omitting the intermediate disc members and shortening the base portion of the trailing pig. As the extruder pigs progress through the CT string 50 , they may apply a uniform thickness coating of the material onto the interior surface of the CT string 50 . After a layer of coating material has been applied, the CT string 50 may be subjected to a drying or curing process to insure the coating bonds to the tubing 50 . For instance, dry air may be passed through the tubing to dry the coating or the tubing may be subjected to heat to cure the lining material thereby creating a mechanical bond between the coating and the tubing 50 . Additional layers may be applied. Each layer may have a thickness of less than 0.0015 inch and, if multi-layer, the aggregate thickness of the coating may be less than 0.004 inch.
[0022] FIG. 2A is a longitudinal cross-section of a trail bypass pig 200 of the pigtrain 1 . FIG. 2B is a radial cross-section of the trail bypass pig 200 . The pig 200 may include a body 205 , a tail plate 207 , one or more brushes 210 , and a bypass 215 . A longitudinal axis L is shown for reference. The body 205 may be made from a flexible material, such as a polymer. The polymer may be foamed polymer, such as polyurethane, or a non-foamed polymer. The body 205 may be bullet-shaped and include a nose portion 205 n, a tail portion 205 t and a cylindrical portion 205 c. The tail portion 205 t may be concave or flat. The nose portion 205 n may be conical, hemispherical or hemi-ellipsoidal. Alternatively, the nose portion 205 n may instead be a second tail portion so that the pig 200 is bidirectional. The tail plate 207 may be bonded to the tail portion 205 n during molding of the body 205 . The shape of the tail plate 207 may correspond to the tail portion 205 t. The tail plate 207 may be made from a (non-foamed) polymer, such as polyurethane.
[0023] The brushes 210 may each extend along an outer surface of the body 205 . Each brush 210 may include a base 211 and bristles 212 embedded therein along a length and a width thereof. The bristles 212 may be made from a metal or alloy, such as steel, or a polymer. Alternatively, grains of abrasive material, such as sand, glass, diamond dust, or carbide (i.e., silicon or tungsten) may be embedded in the base 211 instead of the bristles 212 . Each base 211 may be a strip made from a (non-foamed) polymer, such as polyurethane, ploychloroprene, or polyisoprene. Each base 211 may be a cylindrical segment to conform to the outer surface of the cylindrical portion 205 c . Each base 211 may be longitudinally straight. Alternatively, each base 211 may extend longitudinally and tangentially along the body 205 in a helical orientation or a single base 211 may be helically wound along the body 205 , thereby rotating the pig as the pig travels longitudinally through a tubular string. This spiral motion may serve to more evenly distribute wear to the brushes 210 . Alternatively, scrapers may be used instead of brushes. Alternatively, the brushes may be omitted.
[0024] Each brush 210 may extend from the tail plate 207 or portion 205 t, along the cylindrical portion 205 c, and over a portion of the nose 205 n. Each brush 210 may be bonded to the body by an adhesive 208 , such as a (non-foamed) polymer, such as polyurethane, ploychloroprene, or polyisoprene. The adhesive 208 may be applied around the cylindrical portion 205 c, over the nose 205 n, and an outer surface of the tail plate 205 t so that the adhesive serves as an overcoat 208 for the body 205 as well as an adhesive for the brushes 210 . A tail coat 209 may be applied to the rear surface of the tail plate 207 and the bases 211 . The tail coat 209 may be a (non-foamed) polymer, such as polyurethane, ploychloroprene, or polyisoprene. The brushes 210 may be tangentially spaced around the body 205 , thereby defining a bypass 215 between each brush 210 . The bypasses 215 may each be channels extending along a length of the brushes 210 . Relative to the bypasses 215 , the brushes 210 may substantially occupy the outer surface of the cylindrical portion 205 c, such as more than half, at least two-thirds, at least three-quarters, or at least nine-tenths of the outer surface.
[0025] An outer diameter of the cylindrical portion 205 c may be equal to, slightly greater than, or slightly less than an inner diameter of the CT string 50 . Having interference between the pig 200 and the CT string 50 may ensure tight engagement of the bristles 212 with the inner surface of the CT string 50 .
[0026] FIG. 3A is a longitudinal cross-section of a bypass pig 300 , according to another embodiment of the present invention. FIG. 3B is an end view of the bypass pig 300 . The pig 300 may include a mandrel 305 , a front seal 320 f, a rear seal 320 r, a brush 310 , and a bypass 315 . The mandrel 305 may be a rod having a threaded outer surface and made from a flexible material, such as a polymer. Alternatively, the mandrel 305 may be a threaded tubular capped at each longitudinal end thereof.
[0027] The brush 310 may extend along an outer surface of the mandrel 305 . The brush 310 may include a base 311 and bristles 312 bonded thereto along a length and width thereof. The base 311 may be a helically wound strip or channel made from a metal or alloy, such as steel. The bristles 312 may be made from a metal or alloy, such as steel, or a polymer. Alternatively, a scraper may be used instead of a brush. Alternatively, the brush may be omitted.
[0028] The seals 320 f,r may each include a hub portion 321 , a disc portion 322 , and one or more bypasses 315 . The front and rear designations may be arbitrary as the pig 300 may be bidirectional. The seals 320 f,r may each be made from a polymer, such as polyurethane, ploychloroprene, or polyisoprene. An inner surface of the hub portion 321 may be threaded corresponding to the threaded outer surface of the mandrel 305 . An inner end of each hub portion 321 may abut a respective end of the base 311 , thereby retaining the brush 310 on the mandrel 305 . The bypasses 315 may each be a channel formed in an outer surface of each of the disc portions 322 and extending longitudinally therethrough. Alternatively, the bypasses may each be a hole formed longitudinally through each of the disc portions 322 . The bypasses 315 may be tangentially spaced around each of the disc portions 322 . Alternatively, each hub 321 may be a separate member made from a polymer, such as nylon, and bonded to the disc 322 . Alternatively, nuts made from a polymer, such as nylon, may be used to straddle the disc portion 322 and the base 311 instead of the hub 321 . Alternatively, cups may be used instead of the discs 322 . Alternatively, the bypasses 315 of the front seal 320 f may be misaligned with the bypasses 315 of the rear seal 320 r. Additionally, the hubs or nuts may be bonded to the mandrel after threaded connection.
[0029] An outer diameter of each disc portion 322 may be equal to or slightly greater than an inner diameter of the CT string 50 to ensure tight sealing engagement of the discs 322 with the CT string 50 . The bristles 312 may radially extend from the base 311 to, or slightly outward past the outer diameter of the disc portions 322 to ensure tight engagement of the bristles 312 with the CT string 50 .
[0030] Returning to FIGS. 1 and 1A , as the pigtrain 1 travels through the CT string 50 , bristles 212 , 312 of each pig 200 , 300 may drag along an inner surface of the CT string 50 . A portion of the propellant P may bypass the pigtrain 1 via the bypasses 215 , 315 . As the bypassed portion of the propellant P exits the bypasses 215 , 315 , a fluid (liquid and/or gas) jet T may be created proximately in front of the lead pig 300 , thereby facilitating removal of fluid, such as residual liquid, from the inner surface of the CT string 50 . A velocity of the fluid jet T may be sufficient to disrupt the boundary layer, thereby churning the fluid. Locating the bypass along an outer portion of the pig 1 advantageously maintains increased (i.e., maximum) local velocity of the jet T at an inner surface of the CT string 50 where the drying is occurring. The bristles 212 , 312 may also serve to disrupt and disengage moisture droplets clinging to the CT string inner surface, thereby allowing the jet T to continuously move the moisture ahead of the pigtrain 1 and out of the CT string 50 .
[0031] A number and length of the pigs 200 , 300 may determine the amount of “drag” created by the brushes against the interior wall of the string. The amount of propellant force required to push the pigtrain 1 through the CT string 50 may also determine how much of the propellant P bypasses the pigtrain 1 at the inner surface of the tubing 50 and brush interface, thereby facilitating the removal of fluids ahead of the pigtrain 1 as the pigtrain moves through the CT string 50 . Conventional pigs inserted into a CT string and driven with propellant serve to redistribute any residual liquid in the string over a length of the string. Once the propellant is stopped after running conventional pigs, the residual, redistributed fluid simply returns to the 6 o'clock position in the coil bed wraps and forms a corrosive point in the string bed wraps. Due to the nature of the pigs 200 , 300 creating a predetermined drag force on the pigtrain 1 , at least a portion, such as a substantial portion, of the propellant P bypasses the pigtrain and creates the jet T of propellant P sufficient to move any liquid remaining in the CT string 50 ahead of the pigtrain 1 . Once the pigtrain 1 reaches the end of the CT string 50 , at least a portion, such as a substantial portion or all, of the remaining liquid has been forced out of the CT string 50 ahead of the pigtrain 1 leaving behind only the dry propellant P used to force the pigtrain 1 through the CT string 50 .
[0032] Alternatively, only one of the bypass pigs 200 , 300 may be deployed to dry the CT string 50 instead of the pigtrain 1 . Alternatively, bypass pig 200 may be the lead pig and bypass pig 300 may be the trail pig. Alternatively, the pigtrain 1 may include a plurality of lead pigs 300 and one trail pig 200 . Alternatively, the pigtrain 1 may include one lead pig 300 and a plurality of trail pigs 200 . Alternatively, the pigtrain 1 may include a plurality of lead pigs 300 and a plurality of trail pigs 200 . Alternatively, the pigtrain 1 may include only a plurality of the pigs 300 . Alternatively, the pigtrain 1 may include a plurality of the pigs 200 .
[0033] Alternatively, the bypass 215 may be centrally formed through the body 205 and/or the bypass 315 may be centrally formed through the mandrel 305 .
[0034] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | Embodiments of the present invention generally relate to a method of drying a tubular string to prevent bedwrap corrosion. In one embodiment, a method of drying a tubular string includes deploying a first bypass pig in the tubular string. The method further includes injecting propellant behind the first bypass pig, thereby driving the first bypass pig through the tubular string. A portion of the propellant bypasses the first bypass pig, thereby drying an inner surface of the tubular string. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a system for detecting the number of layers of a few-layer graphene, especially to a system with an image analysis and processing means. The present invention also relates to a method for detecting the number of layers of a few-layer graphene, especially to a method using an image analysis and processing means.
[0003] 2. Description of the Prior Art
[0004] The visualization of graphene is regarded as an issue of increasing importance to the developing graphite technology, especially regarding confirming the number (“N”) of layers of a few-layer graphene (hereinafter “FLG”). Conventional techniques for distinguishing number of layers of FLG include: Raman spectroscopy, transmission spectroscopy, atomic force microscopy (hereinafter “AFM”) and optical microscopy.
A. Raman Spectroscopy and Transmission Spectroscopy
[0005] As described in reference 17, Raman spectroscopy allows detection of number of layers of an FLG by changes in G-band Raman intensity and differences in 2D-band.
[0006] Reference 19 further describes an application of Raman spectroscopy on a silica/silicon (SiO 2 /Si) substrate for counting the number of atomic layers of an FLG. The counting via Raman spectroscopy of the number of atomic layers of the FLG on a silica/silicon substrate is accomplished by examining the sum of intensities of phonon peaks for graphene and silicon so as to obtain information for the number of the layers of the FLG, even if the number of layers is larger than four (N>4).
[0007] It is also revealed in reference 18 that the transmittance of a single-layer graphene is 97.7%, which indicates that information for the number of the layers of an FLG may be obtained by examining the transmittance of the FLG.
[0008] Validation of the information obtained with the aforementioned techniques based on Raman spectroscopy or transmission spectroscopy, however, requires verifications that are significantly time-consuming and labor-intensive. For example, it requires three hours to verify and accomplish a task for examining an FLG having an area of 50 μm 2 . In addition, the technique based on Raman spectroscopy bears certain vague zones within which the number of layers of an FLG cannot be determined.
B. Atomic Force Microscopy
[0009] In accordance with reference 19, the thickness of a single-layer graphene is 0.34 nm. A technique based on AFM detects the roughness of the surface of an FLG and thereby obtains information of the number of layers of the FLG. It is to be noted that such a technique based on AFM also requires a significant amount of time to complete a measurement.
C. Optical Microscopy
[0010] A technique based on optical microscopy, such as one described in reference 14, may be employed to more thoroughly analyze the color of an FLG on a dielectric layer or substrate made of silica, silicon, silicon nitride or aluminum oxide, so as to distinguish different thin-film-optical characteristics of FLGs having different numbers of layers.
[0011] The technique reference 12 relates to a method for examining number of layers of an FLG on specific substrates via microscopic imaging skills. Reference 12 has found that it is possible and feasible to detect the number of layers of an FLG on a 300 nm layer of silicon, whereby the silicon layer is formed on a silica substrate. Furthermore, an FLG on a 100 nm layer of silicon is most visualizable in terms of determining the number of layers of the FLG. Reference 12 also indicates that a silica/silicon substrate with a 285 nm oxide layer significantly increases the visualizability of an FLG thereon, the rationale of which has been verified by color difference calculations.
[0012] Reference 13 has discussed a multispectral optical microscopic method for distinguishing and measuring effective optical characteristics of a graphite of nanometer-level thickness as a basal material. Such basal material is formed on a silicon substrate on a thin insulation layer. Selecting suitable optical characteristics and a dielectric layer of proper thickness allows revealing of the contrast of an FLG and the substrate. The effective refractive index and optical absorption coefficient of a graphene oxide, thermally reduced graphene oxide as well as FLG are obtained by comparing the estimated and measured differences thereof.
[0013] Reference 15 has demonstrated that the measurement for number of layers of FLGs on different substrates made of silicon carbide, silica/silicon, quartz, silicon and glass are subject to the different lattice constants and the electronic structures. Reference 15 has also indicated that an FLG on a substrate of quartz or silica/silicon demonstrates higher contrast of color difference.
[0014] Reference 14 has disclosed a conventional technology using light sources of different wavelength ranges for color difference simulation of FLGs on silica/silicon substrate, silicon nitride substrate and aluminum oxide substrate. The conventional technology of reference 14 has taught that the silicon nitride substrate is a suitable substrate for an FLG to be identified, while the silica/silicon substrate and the aluminum oxide substrate are suitable for graphene thin films of average and high number of layers.
[0015] Reference 16 is related to a color difference analyzing method performed on FLGs deposited on silica/silicon and silica/air substrates. Reference 16 has described the colors of FLGs and graphene-oxides deposited on different dielectric layers. Reference 16 has also presented analyses of thicknesses of materials, types of dielectric layers, and existence of back silicon substrates. It has been indicated that the graphene-oxide layer periodically alters its color with the increase of the thickness of the material. The graphene layer on the same substrate, however, has demonstrated saturated and constant color without periodical alternation.
[0016] As the foregoing literatures have suggested, conventional technologies may employ optical microscopy, especially multispectral optical microscopy, to expedite imaging so as to provide a rapid and intuitive method for detecting number of layers of FLG. The conventional technologies employing optical microscopy, however, are not applicable without substrates of specific thicknesses. It is also to be noted that, these conventional technologies are not feasible with transparent substrates.
[0017] Furthermore, conventional technologies that employ optical microscopy to examine number of layers of FLGs are indeed capable of visually recognizing the number of layers through microscopic means. For example, the number of layers of an FLG deposited on a 300-nm silica dielectric layer of a silicon substrate may be detected using the aforementioned conventional means. In order to make the conventional optical microscopic technologies feasible, it is, however, necessary to make the FLG with a method having increased steps and manufacture processes.
[0018] The conventional optical microscopic technologies fail to visualize distinguishable contrast for examining numbers of layers of FLGs. For example, the contrast obtainable when observing a 5-layer FLG printed on a glass substrate with conventional optical microscopic means is barely visible for examining the number of layers of an FLG.
[0019] To overcome the shortcomings, the present invention provides a system and a method for the detection of the number of graphene layers to mitigate or obviate the aforementioned problems, such as the time-consuming and labor-intensive verifications for the techniques based on Raman spectroscopy or transmission spectroscopy, the expensive instruments and time-consuming measurements of the technique based on AFM, and the restrictions on substrate thickness and transparency and the lack of visible contrast of the conventional technologies based on optical microscopy.
SUMMARY OF THE INVENTION
[0020] The main objective of the present invention is to provide a system for the detection of the number of graphene layers. Another aspect of the present invention is to provide a method for the detection of the number of graphene layers.
[0021] The system in accordance with the present invention has a visualization module, an acquisition module and a reproduction module. The visualization module holds and illuminates an FLG sample. The acquisition module performs an optical observation on the FLG sample. The reproduction module is operably connected to the acquisition module to provide information of detection of a number of layers of the FLG for reproducing a multispectral color image.
[0022] The method in accordance with the present invention has a spectral database construction process and a multispectral image reproduction process.
[0023] The spectral database construction process has a spectra-analyzing step, a principal component analysis (hereinafter “PCA”) step, and a database constructing step. In the spectra-analyzing step, spectral analyses are performed for FLGs of different numbers of layers on different substrates, based on which resulting information is obtained. In the PCA step, PCA is performed with the resulting information to obtain a distinguishing formula. In the database constructing step, a database is built based on the resulting information of the spectral analyses and the distinguishing formula to present a relationship between a number of layers of an FLG and the distinguishing formula.
[0024] The multispectral image reproduction process has an acquisition step, an analyzing step, a categorizing step, an enhancing step, a reproducing step, and an examining step. In the acquisition step, an image of an FLG is acquired. In the analyzing step, the image is analyzed to obtain a transmission spectrum of the FLG. In the categorizing step, the transmission spectrum is categorized according to the aforementioned database constructed via spectral analysis and PCA so as to obtain a categorization result. In the enhancing step, a simulation spectrum is determined based on the categorization result. In the reproducing step, a color image is reproduced with the simulation spectrum. In the examining step, a number of layers of the FLG is determined by examining the color image.
[0025] The system and the method in accordance with the present invention employ multispectral image reproduction process implemented with means such as optical microscopes and charge-coupled devices (hereinafter “CCD”) to provide rapid detection of numbers of layers of FLGs on transparent or non-transparent substrates. The application of the present invention in relevant industries expedites validation and/or verification of the number of layers of an FLG product and improves the quality control efficiency thereof.
[0026] The present invention utilizes colorimetric means such as multispectral imaging based on spectra demonstrated owing to inter-layer destructive interference or inter-layer constructive interference. With PCA and quantification of spectral information, optical microscopic images of FLGs having different numbers of layers may be categorized into groups defined by the proportionality coefficient of a first PCA and a second PCA, so as to provide a system and a method for analyzing numbers of layers of FLGs.
[0027] Specifically, the present invention employs multispectral imaging techniques combining PCA for threshold determination and obtains reproduced images of FLGs having different numbers of layers, in order to rapidly detect a number of layers of an FLG.
[0028] As a result, the present invention mitigates or obviates the problems of the prior art and has overcome the restrictions of substrate thickness and structure. The present invention is capable of readily and correctively detecting numbers of layers of FLGs. Furthermore, the present invention employs multispectral optical microscopy, PCA, color corresponding conversion and linear regression to reproduce color for an FLG image without adjusting color alternation owing to illumination of microscopic imaging means. The straightforward and simple algorithms and the structure of the apparatuses for the method and system in accordance with the present invention have effectively implemented detection and analysis for FLGs, thereby saving the time and intense labor for the conventional technologies without relying on time-consuming measurements using expensive instruments such as AFM. In other words, the present invention indeed provides an effective, low-cost and time-saving technique to conveniently detect numbers of layers of FLGs.
[0029] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic diagram of a system in accordance with the present invention;
[0031] FIG. 2 is another schematic diagram of the system in FIG. 1 ;
[0032] FIG. 3 is a grayscale image of an FLG on a glass substrate obtained using Raman spectroscopy analysis, whereby grayscales corresponding to numbers of layers of the FLG are marked with numerical symbols 0 to 5.
[0033] FIG. 4 is a grayscale image of the FLG FIG. 3 obtained using the system and method in accordance with the present invention, whereby grayscales corresponding to numbers of layers of the FLG are marked with numerical symbols 0 to 5.
[0034] FIG. 5 is an image of a 3-layer FLG on a silica/silicon substrate;
[0035] FIG. 6 is a top view of a 5-layer FLG on a glass substrate;
[0036] FIG. 7 is a schematic diagram of the FLG in FIG. 6 ;
[0037] FIG. 8 is a schematic top view of the FLG in FIG. 6 ;
[0038] FIG. 9 is an image of the FLG in FIG. 6 , whereby ribbon regions of different numbers of layers are marked with dash lines and symbols 1 LG to 5 LG (1-layer graphene to 5-layer graphene.) One square area within the 5 LG ribbon region is marked out, and so are four square areas respectively covering two ribbon regions of different layers;
[0039] FIG. 10 is an image of the square area marked out in FIG. 9 covering the 5 LG and 4 LG ribbons;
[0040] FIG. 11 is an image of the square area marked out in FIG. 9 covering the 4 LG and 3 LG ribbons;
[0041] FIG. 12 is an image of the square area marked out in FIG. 9 covering the 3 LG and 2 LG ribbons;
[0042] FIG. 13 is an image of the square area marked out in FIG. 9 covering the 2 LG and 1 LG ribbons;
[0043] FIG. 14 is an image of the square area marked out in FIG. 9 within the 5 LG ribbon;
[0044] FIG. 15 is a flowchart of the process for determining the matrix of transformation between the information obtained by a spectrometer and the information obtained by an image-acquiring device;
[0045] FIG. 16 is a flowchart of the process for obtaining a simulation spectrum;
[0046] FIG. 17 is a spectral PCA chart for a 3-layer FLG on a silica/silicon substrate;
[0047] FIG. 18 is a spectral PCA chart for a 5-layer FLG on a glass substrate;
[0048] FIG. 19 is a Raman spectroscopic analysis chart for the FLG in FIG. 17 ;
[0049] FIG. 20 is a Raman spectroscopic analysis chart for the FLG in FIG. 18 ;
[0050] FIG. 21 is a chart of 2D-band and G-band ratio of Raman spectroscopic analysis for the FLG in FIG. 18 ;
[0051] FIG. 22 is a chart of layer-wise 2D-band and G-band ratio of Raman spectroscopic analysis for the FLG in FIG. 18 ;
[0052] FIG. 23 is a chart of transmission spectroscopic analysis of the FLG in FIG. 17 ;
[0053] FIG. 24 is a zoomed chart of the chart in FIG. 23 within the range of 90% to 100% transmittance;
[0054] FIG. 25 is a chart of reflection spectroscopic analysis of the FLG in FIG. 17 ;
[0055] FIG. 26 is a chart of transmission spectroscopic analysis of the FLG in FIG. 18 ; and
[0056] FIG. 27 is a chart of reflection spectroscopic analysis of the FLG in FIG. 18 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A. System for Detecting the Number of Layers of FLG
[0057] With reference to FIG. 1 , the system in accordance with the present invention comprises a visualization module 10 , an acquisition module 20 and a multispectral imaging reproduction module 30 .
[0058] The visualization module 10 holds an FLG sample 40 and illuminates the FLG sample 40 with a light source by projecting a light allowing the FLG sample 40 to be optically observed. Specifically, the visualization module 10 comprises a platform member 11 and an illumination member 12 . Preferably, the visualization module 10 further comprises a magnification member 13 , which comprises a structure for magnifying an image of the FLG sample 40 held by the platform member 11 and providing an enlarged image thereof.
[0059] The platform member 11 is for holding the FLG sample 40 . The illumination member 12 provides a light source from which a light is projected to the FLG sample 40 held by the platform member 11 . The magnification member 13 is mounted to the platform member 11 so as to magnify an image of the FLG sample 40 held.
[0060] The visualization module 10 further comprises an optional filter member 14 . The filter member 14 is positioned in a light projecting path from the illumination member 12 . The filter member 14 filters a light from the illumination member 12 in order to provide a filtered light of a band suitable for detecting the FLG sample 40 held by the platform member 11 . The filter member 14 comprises filters, which include red, green, blue, cyan, magenta and yellow filters, to be used alternately or in combination. In addition, in absence of the optional filter member 14 , the illumination member 12 may be an illuminating means capable of using switchable light sources to provide lights of different colors, or lights of different bands.
[0061] With reference to FIG. 2 , the illumination member 12 of the visualization module 10 , other than comprising a reflective structure to reflectively project lights to the FLG sample 40 as having been shown in FIG. 1 , may comprise a beaming structure that operates with a transparent platform member 11 for directly providing lights through the transparent platform member 11 to the FLG sample 40 for observation. Preferably, the illumination member 12 comprises a reflective structure as shown in FIG. 1 and a beaming structure as shown in FIG. 2 and is capable of switching the reflective structure and beaming structure. In other words, the illumination member 12 may comprise a reflective structure which projects a light reflectively to the platform member 11 , a beaming structure which directly provides lights through a transparent platform member 11 , or a switchable structure which comprises both the reflective structure and the beaming structure and is capable of switching the structures.
[0062] The acquisition module 20 comprises a structure for performing an optical observation of the FLG sample 40 . Specifically, the acquisition module 20 is positioned in an output path of the visualization module 10 in which the FLG sample 40 is optically observed, and comprises a CCD member 22 , a lens member 21 and a capturing member 23 .
[0063] The CCD member 22 comprises an array formed with rows and columns of photosensitive units for respectively recording digital signals as pixel information of an electronic image. The CCD member 22 receives an image of the FLG sample 40 of the platform member 11 which has been magnified by the magnification member 13 .
[0064] The lens member 21 is operably connected to the CCD member 22 for focusing the magnified image at the CCD member 22 . Preferably, the lens member 21 focuses a light from the illumination member 12 through the FLG sample 40 at the CCD member 22 .
[0065] The capturing member 23 is an image capturing means operably connected to the CCD member 22 for acquiring information of the magnified image focused by the lens member 21 , which may be a camera or a spectrometer. More preferably, the spectrometer is a spectrometer of model number CS1000A of Konica Minolta or a spectrometer of model number QE65000 of Ocean Optics.
[0066] The reproduction module 30 is operably connected to the acquisition module 20 to provide information of detection of a number of layers of the FLG sample 40 . The reproduction module 30 receives information from the capturing member 23 for the magnified image of the FLG sample 40 and comprises an implementation for a spectral analyzing step 31 , an enhancing step 32 for color image categorizing, and a reproducing step 33 , so as to process and to display the magnified image of the FLG sample 40 for a user to intuitively and rapidly examine a number of layers of the FLG sample 40 .
B. Method for Detecting the Number of Layers of FLG
[0067] The method in accordance with the present invention comprises a spectral database construction process and a multispectral image reproduction process, wherein the spectral database construction process builds a database of numbers of layers of FLGs, based on which a detection by a reproduced multispectral color image for a number of layers of an FLG is performed in the multispectral image reproduction process.
[0068] 1. The database construction process comprises a spectra-analyzing step, a PCA step and a database constructing step.
[0069] (1) In the spectra-analyzing step, spectral analyses are performed for FLGs of different numbers of layers on different substrates, based on which resulting information is obtained. Specifically, the spectra-analyzing step comprises the following procedures:
[0070] (1-a) Preparing FLGs formed on different substrates, for example, developing FLGs on silica/silicon substrates or glass substrates;
[0071] (1-b) Obtaining images of the FLGs, for example, capturing images of the FLGs via an acquisition means such as a microscope and a camera;
[0072] (1-c) Confirming the numbers of layers of the FLGs, for example, via Raman spectroscopy, transmission spectroscopy, or AFM; and
[0073] (1-d) Performing spectral analyses of the transmission spectra of the FLGs and providing resulting information thereof.
[0074] (2) In the PCA step, PCA is performed with the resulting information to obtain a distinguishing formula. Specifically, the PCA step comprises the following procedures:
[0075] (2-a) Performing PCA for the FLGs of different numbers of layers on different substrates and obtaining a PCA result thereof; and
[0076] (2-b) Based on the PCA result, a distinguishing formula as shown in the following Table 1 is determined for FLGs having different numbers of layers on different substrates, provided that y0 is the first principal component and y1 is the second principal component.
[0000]
TABLE 1
number of
layers of FLG
formula
1
−1.9348 < y0 < −1.2234
−0.0047 < y1 < 0.0292
2
−1.1640 < y0 < −0.2308
0.0134 < y1 < 0.0420
3
−0.2308 < y0 < 0.4213
0.0279 < y1 < 0.0560
4
0.4952 < y0 < 1.6962
0.0175 < y1 < 0.0584
5
1.6962 < y0 < 2.4659
−0.0415 < y1 < 0.0175
−0.0415 < y1 < 0.0175
[0077] (3) In the database constructing step, a database is built based on the resulting information of the spectral analyses and the distinguishing formula to present a relationship between a number of layers of an FLG and the distinguishing formula.
[0078] 2. The multispectral image reproduction process comprises an acquisition step, an analyzing step, a categorizing step, an enhancing step, a reproducing step, and an examining step.
[0079] (1) In the acquisition step, an image of an FLG, of which a number of layers is to be detected, is acquired via an acquisition means such as a microscope and a camera.
[0080] (2) In the analyzing step, the image is analyzed to obtain a transmission spectrum of the FLG.
[0081] (3) In the categorizing step, the transmission spectrum is categorized according to the aforementioned database constructed via spectral analysis and PCA so as to obtain a categorization result.
[0082] (4) In the enhancing step, a simulation spectrum is determined based on the categorization result.
[0083] (5) In the reproducing step, a color image is reproduced with the simulation spectrum.
[0084] (6) In the examining step, a number of layers of the FLG is determined by examining the reproduced color image which makes possible an intuitive and rapid examination process.
[0085] Preferably, the method for detecting numbers of layers of FLGs is implemented in the reproduction module 30 . The reproduction module 30 applies the information received from the capturing member 23 of the magnified image of the FLG sample 40 to perform the aforementioned acquisition step for acquiring an image of the FLG sample. After analyzing the image in the analyzing step 31 , a categorization result is obtained in the categorizing step, so as to further enhance and reproduce the magnified image of the FLG sample 40 in the enhancing step 32 and reproducing step 33 , in order to provide a user with a reproduced and enhanced image to perform the examining step for detecting a number of layers of the FLG sample 40 .
[0086] Take a 5-layer FLG on a glass substrate for example, in the case that the FLG in question is analyzed with Raman spectroscopy, a time-consuming and labor-intensive analyzing process would be unavoidable, which makes impossible an intuitive and rapid determination of the number of layers of the FLG. With reference to FIG. 3 , there are considerably vague zones in the results obtained with technique based on Raman spectroscopy, within which the number of layers of the FLG is difficult to be determined.
[0087] Conversely, the system and the method in accordance with the present invention rapidly distinguishes transmission spectra of FLGs and employs color image reproduction to expedite detecting processes for numbers of layers of FLGs, which significantly obviates the shortcomings of the conventional techniques of the prior art.
C. Examples
Example 1
[0088] The instant example relates to preparation of an FLG.
[0089] In the instant example, a copper foil is employed as a catalyst for developing large-area single-layer graphene thin films under a low pressure environment, using methane as a carbon source. Developed graphene thin films are then transferred with polymethylmethacrylate (PMMA) to substrates of various types, such as silica/silicon substrates or glass substrates. Details for preparing the FLG are within the scope of the prior art and thus are omitted here.
[0090] With reference to FIG. 5 , a 3-layer FLG is formed on a silica/silicon substrate. On the silica/silicon substrate there are zero-layer (marked with the symbol “0L”) regions, that is, bare substrate without being covered by graphene, and one-layer (marked with the symbol “1L”), two-layer (marked with the symbol “2L”) and three-layer (marked with the symbol “3L”) regions covered respectively by corresponding layers of graphene.
[0091] With reference to FIG. 6 , a 5-layer FLG formed on a glass substrate is extremely difficult to be directly observed with an optical microscope in terms of distinguishing numbers of layers of the FLG on the substrate. As shown in FIG. 7 , in the instant example, the numbers of layers decrease from a center ribbon region to lateral regions. The ribbon regions are partitioned as shown in FIG. 8 and areas as demonstrated in FIG. 9 and FIGS. 10 to 14 are selected for analyses.
Example 2
[0092] The instant example relates to a matrix of transformation between a spectrometer and an image-acquiring device. The image-acquiring device employed in the instant example comprises an optical microscope and a CCD camera operably connected to the microscope.
[0093] The spectrometer employed in the instant example is model number QE65000 spectrometer of Ocean Optics. The spectrometer is used to obtain transmission spectra of the 24 colors listed in Macbeth ColorChecker within the visible band of spectrum.
[0094] A model is built by multispectral calculation based on the obtained transmission spectra of the 24 colors. The color differences between simulated colors and the image-acquiring device are shown in Table 2, which lists the 24 colors used to build modules for image reproduction as well as the 24 colors' respective reflection spectra and the color differences between simulation colors and microscopic colors. In Table 2, the 24 colors are numbered and listed in reversed order of the indices in the Macbeth ColorChecker ( Journal of Applied Photographic Engineering 2:95-99 (1976)). A simulation spectrum is generated based on the simulated colors to find the correlation between the spectrometer and the image-acquiring device, for analyzing the differences of FLGs of different numbers of layers.
[0000]
TABLE 2
No.
Color
Color difference
1
Black
5.644917
2
Neutral 3.5
4.009531
3
Neutral 5
2.192149
4
Neutral 6.5
1.652081
5
Neutral 8
3.204953
6
White
1.871073
7
Cyan
5.15552
8
Magenta
5.373234
9
Yellow
3.81115
10
Red
1.631564
11
Green
5.384228
12
Blue
5.495808
13
Orange yellow
5.052626
14
Yellow green
3.438659
15
Purple
5.58387
16
Moderate red
2.627343
17
Purplish blue
4.59063
18
Orange
3.64488
19
Bluish green
2.233358
20
Blue flower
4.568302
21
Foliage
4.429298
22
Blue sky
7.24369
23
light skin
6.52435
24
Dark skin
5.741196
[0095] In the instant example, a process as shown in FIG. 15 is employed to determine the matrix of transformation between the information obtained by the spectrometer and the information obtained by the image-acquiring device in order to acquire the transmission spectrum for every pixel of each image.
[0096] For convenience for analyzing, in the instant example the foregoing transmission spectra are sorted into a matrix of 401 rows and 24 columns (“401*24 matrix”). Each row of the 401*24 matrix stands for the intensity of corresponding wavelength, while each column stands for the number of the colors.
[0097] Further with the process as shown in FIG. 16 , a simulation spectrum is obtained. Six sets of eigenvectors (6*401) and corresponding six eigenvalues (6*24) are obtained via eigensystem and PCA, as shown in the following Equation 1.
[0000] [α] T =[D] T p inv[ E] [Equation 1]
[0098] In Equation 1, “pinv” is a false inverse. The information simultaneously detected and acquired for these colors by the image-acquiring device with the optical microscopic environment is output in sRGB JPEG format. With computational calculation, the R, G and B values (0 to 255) of the color of each image information are obtained and converted into R srgb , G srgb and B srgb within a smaller scale of 0 to 1, which, with the following Equations 2 to 4, converts the foregoing RGB values into the XYZ tristimulus of CIE standard.
[0000]
[
X
Y
Z
]
=
[
T
]
[
f
(
R
srgb
)
f
(
G
srgb
)
f
(
B
srgb
)
]
Whereas
:
[
Equation
2
]
[
T
]
=
[
0.4104
0.3576
0.1805
0.2126
0.7152
0.0722
0.0193
0.1192
0.9505
]
[
Equation
3
]
f
(
n
)
=
{
(
n
+
0.055
1.055
)
2.2
,
n
>
0.04045
(
n
12.92
)
,
otherwise
[
Equation
4
]
[0099] The reference white of the sRGB color space is defined as the reference white under standard illuminant D65 light source, which is different from the reference white of the reflective spectrum obtained with the spectrometer under a halogen light source. Thus the RGB values have to be adjusted via chromatic adaptation. In order to accurately estimate the spectral values of the colors, calibration of the image-acquiring device is also necessary.
[0100] Similarly, the reflective spectrum obtained with the spectrometer is converted to the XYZ tristimulus of the CIE standard with the following Equations 5 to 8.
[0000]
X
=
k
∫
380
nm
780
nm
S
(
λ
)
R
(
λ
)
x
_
(
λ
)
λ
[
Equation
5
]
Y
=
k
∫
380
nm
780
nm
S
(
λ
)
R
(
λ
)
y
_
(
λ
)
λ
[
Equation
6
]
Z
=
k
∫
380
nm
780
nm
S
(
λ
)
R
(
λ
)
y
_
(
λ
)
λ
Whereas
:
[
Equation
7
]
k
=
100
/
∫
380
nm
780
nm
S
(
λ
)
y
_
(
λ
)
λ
[
Equation
8
]
[0101] After chromatic adaptation undergone, the RGB values of the camera are converted into XYZ values as matrix [A]. The correlation between the spectrometer and the camera is obtained via 3-degree polynomial regression. The matrix of 3-degree polynomial regression is shown in Equation 9.
[0000] [ C]=[A]p inv[ B] [Equation 9]
[0000] Whereas:
[0000] [ B]=[ 1, R,G,B,RG,GB,BR,R 2 ,G 2 ,B 2 ,RGB,R 3 ,G 3 ,B 3 ,RG 2 ,RB 2 ,GR 2 ,GB 2 ,BR 2 ,BG 2 ] T [Equation 10]
[0102] The “R”, “G” and “B” are values obtained by the image-acquiring device corresponding to each color. The colors are converted from RGB to XYZ tristimulus of the CIE standard as matrix [β], and the matrix of transformation, [M], between the spectrometer and the image-acquiring device is obtained via Equation 11.
[0000] [ M]=[α]p inv[β] [Equation 11]
Example 3
[0103] The instant example relates to color-reproduction using simulation spectra.
[0104] Every pixel of the image obtained by the spectrometer are multiplied by RGB to generate linear regression matrix [C], which gives corresponding XYZ values with calculation with Equations 2 to 4. The simulation spectrum of each color (380 nm to 780 nm band) is obtained via Equation 12.
[0000]
[
Spectra
]
380
-
780
nm
=
[
E
]
[
M
]
[
X
Y
Z
]
[
Equation
12
]
[0105] With the technique of the present invention, the spectrum obtained with the spectrometer under halogen light source is divided by the spectrum obtained with the image-acquiring device under the image-acquiring illumination environment and then multiplied by a spectrum of a new substitution light source. The technique of the present invention makes possible the reproduction of colors under the substitution light source, which may be any light source.
[0106] In order to confirm the feasibility of color reproduction, the error between the actual spectrum and the simulation spectrum is evaluated using color difference formulae in the instant example, a process of which is demonstrated as follows:
[0107] A. The tristimulus XYZ values obtained with the spectrometer and the image-acquiring device are converted into chromatic coordinate values (L*, a*, b*) of the CIE 1976 space, whereas:
[0000]
L
*
=
116
f
(
Y
Y
n
)
-
16
[
Equation
13
]
a
*
=
500
[
f
(
X
X
n
)
-
f
(
Y
Y
n
)
]
[
Equation
14
]
b
*
=
200
[
f
(
Y
Y
n
)
-
f
(
Z
Z
n
)
]
[
Equation
15
]
f
(
n
)
=
{
n
1
3
,
n
>
0.008856
7.787
n
+
0.137931
,
otherwise
[
Equation
16
]
[0108] B. The Euclid distance of two points in the CIE 1976 chromatic coordinate system (or the color difference) is calculated:
[0000] Δ E ab *=√{square root over ((Δ L *) 2 +(Δ a *) 2 +(Δ b *) 2 )}{square root over ((Δ L *) 2 +(Δ a *) 2 +(Δ b *) 2 )}{square root over ((Δ L *) 2 +(Δ a *) 2 +(Δ b *) 2 )} [Equation 17]
[0109] The color differences of the aforementioned 24 colors are as shown in Table 2. The average color difference is 4.21, which indicates that the instant example has demonstrated that the technique of the present invention is capable of providing an effect of color reproduction and thus suitable for the application of color display.
Example 4
[0110] The instant example relates to PCA for principal component scores calculation for categorizing the spectra of a 3-layer FLG on a silica/silicon substrate and a 5-layer FLG on a glass substrate.
[0111] With reference to FIGS. 17 and 18 , the principal component scores simplify high-dimensional data into lower-dimensional data for analyses with a projection in an eigenvector space. The formula of principal component scores is as shown in Equation 18.
[0000] y j =a j1 ( x 1i − x 1 )+ a j2 ( x 2i − x 2 )+ . . . + a jp ( x pi − x p ) [Equation 18]
[0112] x 1i , x 2i . . . x pi are intensities corresponding to the first, second, . . . , p-th wavelengths, while x 1 , x 2 , . . . , x p are average intensities corresponding to the first, second, . . . , p-th wavelengths. a j1 , a j2 , . . . , a jp are coefficients of the eigenvector of the covariance matrix of the spectrum.
[0113] As for PCA, the first principal component, being a general indicator, provides the most abundant information of the original data. The second principal component and the third principal component also demonstrate partial information of the original data, which are useful for further subdividing categorized groups. In order to gain a clear picture of the distribution of the data, succeeding PCA is performed for each group to demonstrate the range of the group in an ellipse as shown in Equation 19:
[0000]
(
a
1
x
+
b
1
y
+
c
1
)
2
d
1
2
+
(
a
2
x
+
b
2
y
+
c
2
)
2
d
2
2
=
1
[
Equation
19
]
[0114] a 1 , b 1 , a 2 , b 2 are coefficients of the eigenvector of the inverse covariance matrix of the group, whose physical meaning is rotation around the coordinate axis. c 1 , c 2 are the averages of the data of the group. Since all the data with the group are projected in PCA, it is necessary to relocate the center of the ellipse back to the original space due to the projection of the original data occurring during the PCA. d 1 and d 2 are eigenvalues of the covariance matrix, whose physical meanings are half of the major and minor axes of the ellipse.
Example 5
[0115] The instant example relates to confirmation of the effect of the present invention with Raman spectroscopic analyses.
[0116] Raman Effect may be used to observe molecular structures, molecular vibration and rotation energy levels, may be located within a molecule functional groups or chemical bonds, and quantitatively analyze complex molecular mixtures. Raman scattering is due to the vibration or rotation of matrix molecules that initiate energy interchange between incident photons and matrix molecules and alter the frequency of the reflected scattering light.
[0117] The instant example employs the microscopic Raman spectrometer of model number Invia 1000 system of Renishaw, which focuses a laser beam through optical microscopic lens at a sample and allows a scattering light to enter the same microscopic lens and to obtain a spectrum therefrom for further analysis.
[0118] The aforementioned Raman spectrometer is used with a 8.6 mW 633 nm red laser beam. A 40× objective lens is used to detect Raman signals.
[0119] As described in reference 22, the Raman shift of an FLG are primarily shown at 1582 cm −1 of G-band and 2676 cm −1 of 2D-band. The Raman spectroscopic analysis chart for the 3-layer FLG on a silica/silicon substrate is shown in FIG. 19 , and the Raman spectroscopic analysis chart for the 5-layer FLG on a glass substrate is shown in FIG. 20 , from which it is evident that FLGs having different numbers of layers demonstrate different Raman shifts, wherein G-band signal intensities increase along with the increase of the number of layers, while the 2D-band signal intensities more significantly shift as the numbers of layers increase.
[0120] In the instant example, the Raman analyses performed with the 3-layer FLG on silica/silicon substrate as shown in FIG. 5 give the results as shown in FIG. 19 , which verify the detection results of the techniques of the present invention match the results of Raman analyses.
[0121] As for the 5-layer FLG on glass substrate as shown in FIGS. 6 to 14 , the results of the techniques of the present invention also match the 2D-band and G-band results of Raman analyses as shown in FIGS. 20 and 21 . With further reference to FIG. 22 , Raman analyses performed on different square-areas also concur with the results obtained with the techniques of the present invention. Comparing aforementioned FIGS. 3 and 4 , it is evident that the present invention makes possible an intuitive and rapid detection of numbers of layers of FLGs, which is superior to the convention methods based on Raman spectroscopy.
Example 6
[0122] The instant example relates to confirmation of the effect of the present invention with transmission spectroscopic analyses.
[0123] Ultraviolet-visible (“UV-Vis”) spectroscopy is a method that employs UV-Vis band of continuous electromagnetic spectrum as a light source for illuminating a sample so as to examine the relative intensity of absorbance.
[0124] Qualification analyses may be performed with UV-Vis spectroscopy, and quantitative analyses are also possible according to Lambert-Beer's Law. When the wavelength is small, a solvent demonstrates strong absorbance, or end-absorbance. The tests are performed within the transparent limitation of the end-absorbance.
[0125] With reference to FIGS. 23 and 26 , the transmission spectrometer is used to verify that FLGs having different numbers of layers on different substrates demonstrate different transmission spectra. As shown in FIGS. 23 and 24 , the transmission spectroscopic analyses of the 3-layer FLG on silica/silicon substrate concur with the result of the techniques of the present invention. The results of reflective spectroscopic analyses as shown in FIG. 25 also concur with the result of the techniques of the present invention.
[0126] Furthermore, with reference to FIG. 26 , transmission spectroscopic analyses give concurring results with the result obtained with the techniques of the present invention. With further reference to FIG. 27 , the results of reflective spectroscopic analyses also concur with the result of the techniques of the present invention.
[0127] As described above, the present invention combines multispectral analysis with PCA to effectively expedite the examination of optical microscopic image of FLG for determining the number of layers thereof. The techniques of the present invention have been verified with conventional methods. For example, the reflection of the specific band increases with the increase of number of layers concurs with Raman analyses. It is evident that the present invention provides techniques for intuitive and rapid detection of numbers of layers of FLGs under low-cost and effective conditions.
[0128] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
REFERENCES
[0129] The following references are cited and incorporated as part of the specification.
[1] H. C. Neto, F. Guinea, N. M. R. Peres, K. S. Novoselov and A. K. Geim: The electronic properties of graphene. Reviews of Modern Physics, 81, 109-162 (2009) [2] K. S. Kim, Y. Z. Houk Jang, S. Y. Lee, J. M. Kim, K. S. Kim, J. H. A. P. Kim, J. Y. Choi and B. H. Hong: Large-scale pattern growth of graphene films for stretchable transparent electrodes. Nature, 457, 706-710 (2009) [3] D. L., MARC B. M. L. SCOTT GILJE, R. B. KANER AND G. G. WALLACE: Processable aqueous dispersions of graphene nanosheets. Nature Nanotechnology, 3, 101-105 (2008)|doi:10.1038/nnano.2007.451 [4] Z. N. Ying W. T. Yu, and Z. Shen: Raman Spectroscopy and Imaging of Graphene. Nano Res 1, 273-291(2008) [5] N. Mohanty, D. Moore, Z. Xu, T. S. Sreeprasad, A. Nagaraja, A. A. Rodriguez1 & V. Berry: Nanotomy-based production of transferable and dispersible graphene nanostructures of controlled shape and size. Nature communications, 3, article number: 844 (2012) [6] Maher F. El-Kady et al: Laser Scribing of High-Performance and Flexible Graphene-Based Electrochemical Capacitors. Science 335 (6074), 1326-1330 (2012) [7] Jae Hun Seol, et al: Two-Dimensional Phonon Transport in Supported Graphene. Science, 328 (5975), 213-216 (2010) [8] H. Yang, et al: Graphene Barristor, A Triode Device with a Gate-Controlled Schottky Barrier. Science, 336 (6085), 1140-1143 (2012) [9] Y. W., H. W. Tong, X. F. Xu, B. Ozyilmaz, and K. P. Loh: Interface Engineering of Layer-by-Layer Stacked Graphene Anodes for High-Performance Organic Solar Cells. Adv. Mater. 23 (13), 1514-1518 (2011) [10] W. Z., C. T. Lin, K. K. Liu, T. Tite, C. Y. Su, C. H. Chang, Y. H. Lee, C. W. Chu, K. H. Wei, J. L. Kuo, and L. J. Li: Opening an Electrical Band Gap of Bilayer Graphene with Molecular Doping. ACS NANO, VOLS NO. 9 7517-7524(2011) [11] S. Lee, K. Lee, C. H. Liu and Z. Zhong: Homogeneous bilayer graphene film based flexible transparent conductor. Nanoscale, 4, 639-644 (2012). DOI: 10.1039/c1nr11574j (2011) [12] P. Blake, E. W. Hill, A. H. Castro Neto, K. S. Novoselov, D. Jiang et al: Making graphene visible, Appl. Phys. Lett., 91, 063124 (2007) [13] I. J. Matthew Pelton, R. P. Dmitriy A. Dikin, S. S. Ovich, S. W. Rotone, M. Hausner, and R. S. Ruoff: Simple Approach for High-Contrast Optical Imaging and Characterization of Graphene-Based Sheets, Nano Letters, 7 (12), 3569-3575 (2007) [14] L. Gao, W. Ren, F. Li, and H. M. Cheng: Total Color Difference for Rapid and Accurate Identification of Graphene, ACS Nano 2 (8), 1625-1633 (2008) [15] Y. Y. Wang, Z. H. Ni, T. Yu, Z. X. Shen, H. M. Wang, Y. H. Wu, W. Chen, and A. T. Shen: Raman Studies of Monolayer Graphene: The Substrate Effect, J. Phys. Chem 10637-10640(2008) [16] I. J., J. S. Rhyee, J. Y. Son, R. S. Ruoff and K. Y. Rhee: Colors of graphene and graphene-oxide multilayers on various substrates. Nanotechnology, 23, 025708 (2012) [17] Z. H. Ni, H. M. Wang, J. Kasim, H. M. Fan, T. Yu, Y. H. Wu, Y. P. Feng, and Z. X. Shen: Graphene Thickness Determination Using Reflection and Contrast Spectroscopy. Nano Lett., 7 (9), 2758-2763 (2007) [18] Y. W. Zhu, S. Murali, W. Cai, X. Li, Ji Won Suk, J. R. Potts, and R. S. Ruoff: Graphene and Graphene Oxide: Synthesis, Properties, and Applications. Adv. Mater., 22 (35), 3906-3924 (2010) [19] Y. K. Koh, M. H. Bae, D. G. Cahill, N. E. Pop: Reliably Counting Atomic Planes of Few-Layer Graphene (n>4). ACS Nano, 5 (1), 269-274 (2011) [20] W. Liu, H. Li, C. Xu, Y. Khatami, K. Banerjee: Synthesis of high-quality monolayer and bilayer graphene on copper using chemical vapor deposition, Carbon, 49 (13), 4122-4130 (2011) [21] J. S. Park, A. Reina, R. Saito, J. Kong, G. Dresselhaus, M. S. Dresselhaus: G band Raman spectra of single, double and triple layer graphene, Carbon, 47 (5), 1303-1310 (2009) [22] M. S. Dresselhaus, G. Dresselhaus, R. Saito, A. Jorio: Raman spectroscopy of carbon nanotubes, Physics Reports, 409 (2), 47-99( 2005 ) [23] A. C. Ferrari, J. C. Meyer, V. Scardaci, Casiraghi, M. Lazzeri, F. Mauri, S. Piscanec, D. Jiang, K. S. Novoselov, S. Roth, and A. K. Geim: Raman Spectrum of Graphene and Graphene Layers, Physical Review Letters, 97, 187401 (2006) | Provided are a system and a method for detecting a number of layers of few-layer graphene employing multispectral image reproduction process to provide rapid detection of numbers of layers of few-layer graphenes on transparent or non-transparent substrates. The application of the system and method in relevant industries expedites validation and/or verification of the number of layers of an FLG product and improves the quality control efficiency thereof. | 6 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/232,267, filed Sep. 13, 2000, and entitled Improved Surface Particle Detector.
FIELD OF THE INVENTION
[0002] This invention relates generally to particle counting for clean room applications, and relates more particularly to an improved device for moving particles off of a surface and into a particle counter and a filter for the purpose of ascertaining contamination levels.
BACKGROUND OF THE INVENTION
[0003] Contamination detection and quantification requirements have become increasingly important, particularly with the rapid evolution of high-tech industries. For example, the semiconductor industry has developed technology for precisely producing microelectronic devices. In order to reliably produce such products, highly stringent contamination standards must be maintained in the production facilities.
[0004] In an effort to control and minimize contamination in crucial stages of a production process, “cleanrooms” are frequently used. A cleanroom is a room in which the air filtration, air distribution, utilities, materials of construction, equipment, and operating procedures are specified and regulated to control airborne particle concentrations to meet appropriate airborne particulate cleanliness classifications.
[0005] It is important to monitor the cleanliness/contamination levels in a cleanroom, especially for detecting particles on a cleanroom surface. Visual inspection techniques have been used with ultraviolet or oblique white light. Ultraviolet light is employed to take advantage of the fact that certain organic particles fluoresce. Alternatively, white light is shined towards the test surface at an angle so as to produce reflections that can be visualized. While the white light technique is slightly more sensitive than the ultraviolet technique, they both suffer from the same limitations. These visual inspection techniques only allow a cursory inspection of the surface conditions. They do not provide quantitative data. Also, the visual inspection techniques, at best, only detect particles that are larger than twenty microns. It is often desirable to detect particles that are less than one micron.
[0006] Another inspection technique involves removing particles from a test surface, by for example, applying a piece of adhesive tape to the test surface. The particles on the tape are then manually quantified by putting the tape under a microscope and visually counting the particles. This technique allows the detection of particles of approximately five microns or larger. The primary disadvantage of this technique is that it is very time consuming, and that it is highly sensitive to variability between operators.
[0007] A third inspection technique is disclosed in U.S. Pat. No. 5,253,538, which is expressly incorporated herein by reference. The '538 patent discloses a device that includes a scanner having at least one opening for receiving particles from the sample surface. The scanner is connected to a tube having first and second ends. The first end of the tube is connected to the scanner and the second end of the tube is connected to a particle counter that employs optical laser technology. The particle counter includes a vacuum generator that causes air to flow from the sample surface through the scanner, through the tube and into the particle counter, where particles contained in the air stream are counted. The '538 patent discloses an inspection method that involves the use of the particle counting device. A background particle level of zero is first established by holding the scanner near the cleanroom supply air and taking repeated readings, or by installing an optional zero-count filter in the particle counter. Next, the hand-held scanner is passed over the sample surface at a constant rate for a predetermined test period. The test cycle is started by pushing the run switch, which is located on the scanner. The particle counter counts and reads out a number corresponding to the average number of particles per unit area. The process is usually repeated several times along adjacent surface areas, each time yielding a “test reading”.
SUMMARY OF THE INVENTION
[0008] The present invention is a device for counting particles on a sample surface. The device includes a scanner having at least one opening for receiving particles from a sample surface, a particle counter for counting particles passed therethrough, a conduit having a first end connected to the scanner and a second end connected to the particle counter, wherein the conduit includes first and second tubes, a sensor and a controller. The particle counter includes a pump for producing an airstream flowing from the scanner opening, through the first tube, through the particle counter, and back to the scanner via the second tube, for carrying the particles to the particle counter for quantitation. The sensor measures a rate of flow of the airstream. The controller controls a speed of the pump in response to the measured rate of flow of the airstream to maintain the airstream at a constant flow rate while the particle counter quantitates the particles in the airstream.
[0009] In another aspect of the present invention, the device includes a scanner having at least one opening for receiving particles from a sample surface, a conduit having a first end connected to the scanner and a second end terminating in a first connector, wherein the conduit includes first and second tubes; a particle counter, electronic indicia, and a controller. The particle counter counts particles passed therethrough, and includes a port for receiving the first connector and a pump for producing an airstream flowing from the scanner opening, through the first tube, through the particle counter, and back to the scanner via the second tube, for carrying the particles to the particle counter for quantitation. The electronic indicia is disposed in at least one of the first connector, the conduit and the scanner for identifying at least one characteristic of the scanner. The controller detects the electronic indicia via the port and first connector, and controls the particle counter in response to the detected electronic indicia.
[0010] In yet one more aspect of the present invention, the device includes a scanner having at least one opening for receiving particles from a sample surface, a particle counter for analyzing particles passed therethrough, and a conduit having a first end connected to the scanner and a second end connected to the particle counter. The conduit includes first and second tubes. The particle counter includes a pump for producing an airstream flowing from the scanner opening, through the first tube, through the particle counter, and back to the scanner via the second tube, for carrying the particles to the particle counter. The particle counter also includes a particle detector for counting the particles in the airstream coming from the scanner, a filter cartridge port through which the airstream flows after passing through the particle detector, and a filter cartridge removably connected to the filter cartridge port for capturing the particles in the airstream after being counted by the particle detector.
[0011] Other objects and features of the present invention will become apparent by a review of the specification, claims and appended figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1A is a perspective view of the particle detector of the present invention.
[0013] [0013]FIG. 1B is a partially broken away view of the particle detector of the present invention.
[0014] [0014]FIGS. 2A and 2B are top and bottom perspective views of the scanner of the present invention.
[0015] [0015]FIG. 3 is a block schematic diagram of the particle counter assembly of the present invention.
[0016] [0016]FIG. 4 is a schematic diagram showing the airstream path in the particle detector of the present invention.
[0017] [0017]FIG. 5 is a partially broken away view of the particle capture filter cartridge and tray of the present invention.
[0018] [0018]FIG. 6 is a partially exploded view of the quick release connection between the conduit and the particle counter assembly of the present invention.
[0019] [0019]FIGS. 7A and 7B are schematic diagrams showing the pneumatic tubing and electrical wiring of the conduit for the scanner head and purge filter head, respectively, of the present invention.
[0020] [0020]FIGS. 8A to 8 F are front views of the control panel and display of the present invention, illustrating the various screens produced by the display.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The present invention is an improved surface particle detector, relative to the particle detector disclosed in U.S. Pat. No. 5,253,538, which is expressly incorporated herein by reference. The present invention advantageously employs in operable combination three primary elements to provide the flexibility of conveniently sampling particles on a wide variety of surfaces, while also providing relative quantitative data with a high degree of precision and repeatability. In broad terms, the invention involves the combination of a state-of-the-art particle counter connected to one of a plurality of specially designed and sized sampling scanners via a flexible conduit. In a preferred embodiment the conduit has two air tubes and electrical wires for supplying and returning air to and from the sample surface and for powering the scanner. The light weight moveable scanner and flexible tube design allow particle sampling on many different types of accessible surfaces. The sample surface may or may not be substantially flat, and may or may not be smooth.
[0022] [0022]FIGS. 1A and 1B show the primary components of the particle detector 10 for analyzing particles on a sample surface. The main detector components include a particle counter assembly 12 , a housing 14 surrounding the particle counter assembly 12 , a scanner probe 16 , and conduit 18 connected between the particle counter assembly 12 and probe 16 .
[0023] Housing 14 includes a base 20 , a shaped top cover 22 , a front plate 24 with an aperture 26 for viewing a display, and a handle 28 . These housing components are shaped to enclose particle counter assembly 12 in a small, lightweight, portable package. The housing can include a heatsink for dissipating heat generated inside the unit. Preferably, housing 14 includes a small circulating fan to normalize air temperature inside the unit so that the unit does not overheat.
[0024] [0024]FIGS. 2A and 2B illustrate the scanner probe 16 , which includes a substantially planar base 30 . The scanner base 30 has a bottom side 32 for interfacing with the sample surface. The scanner base 30 is perpendicularly connected to a scanner handle 34 which includes a control section 35 having run switch 36 for activating the particle detector and an LED light indicating that particle counting is in progress. The conduit 18 includes a pair of tubes 38 and 40 (supply and return hoses) each having a first and a second end. The first ends of the tubes 38 / 40 are connected to the scanner handle 34 , and the second ends are connected to a port 92 in the particle counter assembly 12 . The conduit 18 also includes electrical wiring 44 which electrically connects the scanner probe 16 to the particle counter 12 . The scanner probe 16 fits into a receptacle 15 in the housing 16 for easy storage.
[0025] The base portion 30 of the scanner probe 16 has two coin-shaped portions 46 and 48 which are fastened together by screws 50 . The scanner embodiment shown in FIGS. 2A and 2B is designed primarily for picking up particles off of a substantially flat surface. However, scanners of other shapes which are specifically designed to conform to non-flat sample surfaces could also be used. Coin-shaped portion 46 of the scanner base 30 is also referred to as a face plate, and is preferably made of a material which is impregnated with a friction limiting non-particulating substance, for example, hard black anodized aluminum with Teflon impregnation, type 3, class 2, mil spec A8625D. The scanner handle 34 has two bores 56 and 58 for receiving the supply and return tubes 38 / 40 . Another hole 60 is provided in the handle 34 for receiving the electrical wiring 44 from the conduit 18 .
[0026] The scanner base bottom side 32 is designed to interface with the sample surface. In this embodiment, the bottom side 32 has a hole 62 which is located approximately in the center of the base plate bottom side 32 . The hole 62 is connected to the bore 56 in the scanner handle 34 which is connected to the return tube 40 of conduit 18 . Particles from the sample surface are sucked through the face plate hole 62 for the purpose of counting the particles in the particle counter assembly 12 . The base plate bottom side 32 also has a plurality of smaller holes 64 which converge into the scanner handle bore 58 , which is connected to the air supply tube 38 of conduit 18 . Air is supplied from the particle counter assembly 12 and delivered through the face plate holes 64 onto the sample surface for dislodging and fluidizing particles so that they may be sucked through face plate hole 62 for counting. Face plate bottom side 32 also has intersecting grooves 66 for channeling dislodged particles into face plate hole 62 .
[0027] [0027]FIG. 3 schematically shows the particle counter assembly 12 , which includes a 90-260 VAC-DC converter 70 , a battery charge controller 72 , a batter pack 74 , a differential pressure sensor 78 , a vacuum pump 80 , a laser particle detector 82 , a display controller 84 for controlling a color display 86 and receiving input from switches 88 located on a control panel, all controlled by a system controller 90 . A series of ports are also connected to the controller 90 , including a smart probe port 92 , a calibration signal output port 94 , a user printer port 96 , and a host computer data port 98 . In a preferred embodiment, the controller 90 also includes software for converting numbers of detected particles to numbers of particles per unit area relative to the sample surface.
[0028] The rechargeable battery pack 74 allows the unit to run for about 2 hours of continuous use or 8 hours in normal intermittent use. The system can also run on AC power for stationary applications. The system is targeted to weigh less than 16 lbs. The battery powered, lightweight unit and convenient carrying handle results in a truly portable unit that will enable the user to access areas that previously were difficult to access and to reduce the setup time.
[0029] [0029]FIG. 4 illustrates the airstream path of the particle detector device 10 . The airstream plumbing is a substantially closed loop system, where clean air is supplied to the scanner probe 16 and particles are returned in the air stream that feeds the particle detector 82 . An intake of the vacuum pump 80 is plumbed to the discharge side of the particle detector 82 , with an optional particle capture filter 104 plumbed between the vacuum pump 80 and the particle detector 82 . Plumbed to the discharge side of the vacuum pump 62 is a (HEPA) filter 100 that filters out particles from the flowing air, and an airflow measurement device (such as a differential pressure sensor) 78 that measures the rate of airflow through the system (using a controlled orifice in the airstream path). The discharge side of the filter 100 is plumbed to the supply tube 38 to supply filtered air to the exhaust holes 64 of the scanner probe 16 .
[0030] The vacuum pump 80 creates a partial vacuum through the particle detector 82 , return tube 40 of conduit 18 , and to the scanner opening 62 . The partial vacuum draws air from the sample surface to the particle detector 82 , which is preferably a laser diode light scattering counter known in the art that determines particle count and size. After the particles are analyzed, they are filtered from airstream either by capture filter 104 or HEPA filter 100 , whereafter the airstream is returned to the sample surface via smart probe 92 .
[0031] Differential pressure sensor 78 measures the rate of airflow through the system. Controller 90 adjusts the speed of vacuum pump 80 to maintain the flow rate at the desired level. Flow rate control is important for several reasons. First, for accurate measurements, the flow rate should be the same for each particle measurement for a given scanner probe. Second, different probes 92 will require different flow rates for maximum accuracy. Third, when the probe 92 is scanned across the surface, additional pressure (back pressure) is imposed on the system, both initially as the probe is placed on the surface and as the texture or shape of the surface changes during the scan. It is therefore important to maintain the proper and constant flow rate throughout the entire scan to effectively remove particles from the surface and maintain a high sensitivity for the system.
[0032] The particle capture filter 104 is a removable filter element inserted into the airstream path to capture the particles in the airstream that have just passed through and been counted by the laser particle detector 82 . This allows the user to not only measure the surface cleanliness, but to capture the counted particles for laboratory analysis and identification. In the preferred embodiment, the capture filter 104 is a membrane filter element that is disposed in a sealable, disposable cartridge 108 that inserts into a receptacle 110 connected to the system airstream, as illustrated in FIG. 5. The receptacle 110 and cartridge 108 have pneumatic quick disconnect connectors 112 that mate to connect the filter element 104 to the system airstream. Connectors 112 on the cartridge 108 can be manually capped after being disengaged from the system to prevent contamination of the filter element 104 until laboratory analysis can be performed. The filter cartridge 108 is installed and removed by means of a pullout tray 114 that is similar to a CD ROM. The tray 114 pops partially out from the receptacle 110 when a release button 115 is depressed. The tray 114 is then manually fully opened, and the removable filter cartridge 108 can be installed or removed. A dummy cartridge identical to cartridge 108 but with no filter element 104 inside can be inserted into the receptacle 110 if no capture filter 104 is needed. Sensors, preferably optical sensors, automatically identify the presence or absence of the cartridges, and whether the cartridge includes a filter 104 or is a dummy cartridge. This data is recorded along with the sample record. The vacuum pump 80 is deactivated if no cartridge is detected. The cartridge 108 is sealed when removed from the system, so that it can be sent to an analytical laboratory for analysis of the contamination trapped by the filter media 104 .
[0033] The connection between the conduit 18 and the particle counter assembly is illustrated in FIG. 6. Single quick-release connector 116 and smart probe port 92 are used for both electrical and pneumatic connections. The conduit 18 terminates in the quick release multiconnector 116 that releasably engages with smart probe port 92 , each of which has pneumatic quick disconnect connectors 118 for connecting the air supply and return tubes 38 / 40 to the plumbing of the particle counter assembly 12 . Preferably, these quick disconnect connectors 118 are self sealing when disengaged to prevent contamination of the system airstream tubing. Connector 116 and port 92 also include electrical connectors 120 for supplying power to, and gathering data and signals from, the probe 16 via conduit electrical wiring 44 (i.e. to operate LED 54 and run switch 36 ). Connector 116 includes a release button 122 for quickly releasing the connector from the port 92 .
[0034] Different sizes and types of probes 16 can be used to test different sized or shaped surface areas. Each probe type/size may require a different flow rate and/or a different set of calculations for data analysis. For example, ½ inch, 2-inch and 3-inch diameter scanner probes 16 have been used, some of which need different flow rates to operate correctly. The ½ inch probe may need about ½ cubic feet per minute (CFM) flow rate, while the 2 and 3 inch probes may need 1 CFM. Probes 92 may be called ‘smart’ probes because they include electronic indicia that allows the system controller 90 to automatically recognize one or more characteristics of the probe, such as its size and/or type. The electronic indicia could be an IC chip, electrical circuitry or simply predetermined combinations of electrical pin connections in the probe 16 , in the conduit 18 , or in the multiconnector 116 that is unique to the size/type of probe identified thereby. The controller automatically displays the probe type/size on the control screen, operates the vacuum pump 80 to generate the proper flow rate, and applies the proper formulas for calculating the particle detection results given the electronic indicia identified by the system controller 90 .
[0035] [0035]FIG. 7A illustrates the tubing 38 / 40 and electrical wiring 44 running between the multiconnector 116 and probe head 16 . FIG. 7B illustrates a purge filter 124 that can be attached to the system to clean out accumulated particles from the air lines in the system. The purge filter plugs into the system in the same way probe 16 does, although there is no need for electrical wiring 44 all the way to the purge filter itself. Purge filter 124 completely closes the airstream loop of the system, which can be run to filter out any particles in the system using purge filter 124 , the HEPA filter 100 and the particle capture filter 104 (if connected). Preferably, purge filter 124 filters particles out that are as small as 0.3 microns. The controller 90 will automatically recognize the absence of or type of probe attached to the system, including the purge filter, and run the system accordingly. For example, the vacuum pump 80 is deactivated if no probe or purge filter is detected.
[0036] The particle counter assembly 12 includes a front display panel 86 that is exposed by the aperture 26 in front cover 24 . This front display panel is shown in FIGS. 8A to 8 F, and includes a multicolor screen 126 and a series of touch screen buttons 128 for operating the system. The preferred embodiment includes five screen navigation buttons to select from five different screens (Main: shows overview of system (FIG. 8A); Collect Data: shows current or last particle count data (FIG. 8B); Data Mode: allows user to choose normal full screen (FIG. 8D) or enlarged data modes (FIG. 8C) to better view critical data; View Data: shows previously recorded data (FIG. 8E); and Alarm Setup: allows user to set up alarm limits for each particle size (FIG. 8F).) There is also a Pump On/Off button (for activating/deactivating the vacuum pump 80 ), a Clear button (for clearing the highlighted field), and Navigation buttons (arrow buttons for moving a cursor and a Program button for saving selections on the screen). The large color screen enables the operator to comfortably view a large amount of data, or switch to the “zoom” screen to see only critical count data from a distance. Buttons 128 can be either hard wired keys, or soft keys displayed on a touch-sensitive type display screen 126 .
[0037] The calibration port 94 allows a calibration technician to perform a normal calibration to the laser particle detector 82 without having to open the unit. Data collected is then stored in the particle detector 10 . The system has RS-232 serial and Ethernet communication capability via the data port 98 , so that collected data can be imported into a customers' network or host computer. Data port 98 can also allow the unit to communicate through a network or directly with the internet, which would allow remote access to the unit and the data stored therein, as well as data or instructions that can be displayed on a computer screen. The preferred embodiment also includes multiple levels of password protected access (e.g. factory, owner, user, etc.), with each password level having different rights to make changes to the system or to access certain data.
[0038] The scanner base 30 is preferably perpendicularly connected (but could instead be attached in a parallel fashion) to the scanner handle 34 which includes a control section 52 having the run switch 36 and an LED light 54 for indicating whether the device is counting particles. Activating the pump on/off button on the control panel activates the vacuum pump 80 , which should be run for a minute or two before data is collected. In a preferred embodiment of the invention, activating the run switch 36 while the system is in its standby mode (vacuum motor running but particle counting not activated) causes the system to go into its “counting” mode where particle measurements take place for a predetermined time period (e.g. 3 seconds) and the LED light 54 is activated. After the expiration of the predetermined time period, particle measurements cease and the LED light 54 is deactivated. Audible signals can also be produced to indicate when the instrument is switching between its “counting” and its “standby” modes.
[0039] The device described above is used to obtain a relative cleanliness level by quantitating the released particles from surfaces. Examples of possible test surfaces include tables, shelves, walls, ceilings, benches, product containers or virtually any other kind of surface. Different scanner geometries can be employed for customizing the device to the particular sample surface of interest. The technique can be used to verify cleanliness prior to undertaking some type of clean room procedure. The technique can also be used to evaluate or compare the effectiveness of various cleaning techniques and products.
[0040] In a preferred embodiment of the invention, filtered air is used to disturb the surface particles and a vacuum system collects the particles which are fluidized by the air. Particle levels are measured and recorded in particles per centimeters squared or particles per inch squared using optical/laser technology. The device of the present invention is capable of detecting particles as small as 0.3 microns. The air is filtered to 0.2 microns and supplied to the scanner head, where the same amount of air is pulled through the scanner head to the sensing system for counting and sizing.
[0041] Prior to counting particles, the system should first be checked for zero counting by holding the scanner head towards the clean room supply air and taking repeated counts until the levels are below 5 particles per inch squared. The scanner head is then passed over the sample surface at a rate of 10 LFPM (2 LIPM) for a period of three or six seconds. The test cycle is started from the run switch 36 located in the scanner probe 16 . The scanner probe 16 is moved lightly across the surface assisted by the fluidizing air.
[0042] As this method gives relative cleanliness levels immediately, it is recommended that routine monitoring be performed with historical data being logged for various surfaces and locations in the clean room. It is also recommended that a minimum of six readings be taken for any given area with average levels and maximum allowable single reading levels being established for the various surfaces and areas.
[0043] It is to be understood that the present invention is not limited to the embodiment(s) described above and illustrated herein, but encompasses any and all variations falling within the scope of the appended claims. | A surface particle detector that includes a scanner slidable over a surface, a particle counter for counting particles passed therethrough, and a conduit connected between the scanner and the particle counter. The particle counter includes a pump for creating an airstream for drawing particles from the surface, through the scanner and conduit, to the particle counter, and back to the scanner. A sensor measures the airstream flow rate, and a controller controls the pump speed based upon the sensed airstream flow rate. The conduit attaches to the particle counter via a first connector, which contains electronic indicia identifying the type of scanner attached to the other end of the conduit. The controller controls the particle counter in response to the detected electronic indicia. The particle counter also includes a removable filter cartridge with a filter element that captures the counted particles for laboratory analysis. | 6 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to fuel cells, and more particularly to a polymer electrolyte membrane fuel cell stack having improved fuel concentration across an anode, and efficient cooling across the cathode.
BACKGROUND OF THE INVENTION
[0002] Fuel cells are electrochemical cells in which a free energy change resulting from a fuel oxidation reaction is converted into electrical energy. A typical fuel cell comprises a fuel electrode (anode) and an oxidant electrode (cathode) separated by an ion-conducting electrolyte. The electrodes are connected electrically to a load (such as an electronic circuit) by an external circuit conductor. In the circuit conductor, electric current is transported by the flow of electrons, whereas in the electrolyte it is transported by the flow of ions, such as the hydrogen ion (H + ) in acid electrolytes, or the hydroxyl ion (OH − ) in alkaline electrolytes. In theory, any substance capable of chemical oxidation that can be supplied continuously (as a gas or fluid) can be oxidized galvanically as the fuel at the anode of a fuel cell. Similarly, the oxidant can be any material that can be reduced at a sufficient rate. Gaseous hydrogen has become the fuel of choice for most applications, because of its high reactivity in the presence of suitable catalysts and because of its high power density. Similarly, at the fuel cell cathodes the most common oxidant is gaseous oxygen, which is readily and economically available from air for fuel cells used in terrestrial applications. When gaseous hydrogen and oxygen are used as fuel and oxidant, the electrodes are porous to permit the gas-electrolyte junction area to be as great as possible. The electrodes must be electronic conductors, and possess the appropriate reactivity to give significant reaction rates. At the anode, incoming hydrogen gas is oxidized to produce hydrogen ions (protons) and electrons. Since the electrolyte is a non-electronic conductor, the electrons flow away from the anode via an external electrical circuit. At the cathode, oxygen gas is reduced and reacts with the hydrogen ions migrating through the electrolyte and the incoming electrons from the external circuit to produce water as a byproduct. The byproduct water is typically expelled as vapor at elevated temperatures. The overall reaction that takes place in the fuel cell is the sum of the anode and cathode reactions, with part of the free energy of reaction released directly as electrical energy. The difference between this available free energy and the heat of reaction is produced as heat at the temperature of the fuel cell. It can be seen that as long as hydrogen and oxygen are supplied to the fuel cell, the flow of electric current will be sustained by electronic flow in the external circuit and ionic flow in the electrolyte.
[0003] In practice, a number of these unit fuel cells are normally stacked or ‘ganged’ together to form a fuel cell assembly. A number of individual cells are electrically connected in series by abutting the anode current collector of one cell with the cathode current collector of its nearest neighbor in the stack. Fuel and oxidant are introduced through manifolds into respective cells. The fuel and oxidant flow across the anode and cathode, respectively. One known fuel cell disclosed in U.S. Patent Publication 2004/0038112 A1 shows the fuel and oxidant flowing in serpentine channels across the anode and cathode. However, fuel is consumed as it progresses along the anode, creating an uneven fuel concentration and distribution of power across the anode. Furthermore, the oxidant tends to cool the cells it first contacts much more that the remainder of cells in the stack, causing uneven cooling of the fuel cell assembly resulting in uneven power distribution across the stack. Ideally, the temperature of the cells at the ends of the stack are the same as the cells in the center of the stack
[0004] Accordingly, it is desirable to provide a polymer electrolyte membrane fuel cell stack having evenly distributed fuel concentration from fuel flowing across an anode and improved heat distribution within the fuel cell stack. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY OF THE INVENTION
[0005] A polymer electrolyte membrane fuel cell stack comprises a plurality of membrane electrode assemblies having evenly distributed fuel concentration across an anode, and efficient cooling from the oxidant that flows across a cathode. A first plate has a fuel side with a plurality of serpentine channels formed therein for distributing fuel across the anode, and a second plate has an oxidant side with oxidant channels formed therein for distributing an oxidant across the cathode. The membrane electrode assembly has an even fuel concentration thereacross and the oxidant is routed through the cell for absorbing heat prior to being distributed across the cathode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
[0007] FIG. 1 is an exploded perspective view of a fuel cell in accordance with an exemplary embodiment of the present invention;
[0008] FIG. 2 is a cross sectional view of a portion of the fuel cell taken along the line 2 - 2 of FIG. 1 ;
[0009] FIG. 3 is a plane side view of a plate including fuel channels of the fuel cell of FIG. 1 ;
[0010] FIG. 4 is a plane side view of a plate including oxidant channels of the fuel cell of FIG. 1 ;
[0011] FIG. 5 is an exploded schematic side view of a stack of the fuel cells shown in FIG. 1 ;
[0012] FIG. 6 is a plane view of one backing plate of the fuel cell taken along the line 6 - 6 of FIG. 1 ; and
[0013] FIG. 7 is a plane view of the other backing plate of the fuel cell taken along the line 7 - 7 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
[0015] A polymer electrolyte membrane fuel cell is disclosed that operates at high temperature using membranes that don't require humidification to work. More specifically, the preferred embodiment of the present invention comprises a stack for operating elevated temperature (120-250° C.) polymer electrolyte membrane fuel cells that is compact and lightweight. Low and medium temperature polymer electrolyte membrane stacks (<120° C.) are complicated by water management and cooling issues. Water management is not an issue in polymer electrolyte membrane fuel cells operating at temperatures above 120° C., as long as the membrane is capable of proton conduction independent of humidity. Cooling issues are significantly different when using elevated temperature membrane electrode assemblies compared to “standard” Nafion-type membrane electrode assemblies. The problems that need to be resolved in an elevated temperature polymer electrolyte membrane fuel cell stack include: ensuring even fuel and thermal distribution across the stack, and sufficient thermal management such that operation at current densities <600 mA/cm 2 requires no additional stack-related “balance of plant” (other components required to cool or maintain the temperature in a fuel cell stack, e.g., fans, pumps, cooling channels, coolant fluid/gas, and control circuitry). Also, the stack should have very low pressure drop so that demand on system balance of plant is minimized, and also compact and lightweight to meet certain power density specs. In the stack disclosed herein, stack temperature is controlled by the rate, or stoichiometry, at which the cathode oxidant is supplied. During startup, or when the stack is operated at low load, cathode oxidant is supplied at rates corresponding to a fuel stoichiometry in the range of 1-3. During operation at higher temperatures/load, the rate of the oxidant flow is increased, which withdraws heat more quickly from the stack and reduces temperature. Typically, cathode oxidant flow rates corresponding to reactant stoichiometry 3-10 are sufficient to control the stack temperature when operating at the parameters anticipated for a portable power system. It is important for the temperature of the cells to be even across the length of the stack in order to ensure even power distribution, particularly when operating the stack using reformate fuel containing carbon monoxide impuritites. In practice, it is preferred that the temperature gradient along the length of the stack be less than 30° C. In the stack disclosed herein, the oxidant is passed through the edges of the stack assembly prior to passage across the cathode side of the fuel cell. This method has the advantage of preventing the ends of the stack from becoming excessively cooled during operation, and thus maintain an even stack temperature.
[0016] FIG. 1 is an exploded isometric view showing a single fuel cell 10 according to an exemplary embodiment of the present invention. The fuel cell 10 includes a membrane electrode assembly 12 separated from end plates 14 , 16 by gaskets 18 , 20 , respectively. Gaskets 18 , 20 seal gases between the membrane electrode assembly 12 and both the end plates 14 , 16 within the fuel cell 10 . The gaskets 18 , 20 preferably comprise Teflon® materials such as Teflon coated fiberglass sheet, but may also comprise, for example, Viton® FEP (fluorinated ethylene propylene), and Nowoflon® PFA (perfluoroalkoxy). The end plates 14 , 16 may comprise, for example, a metal.
[0017] The membrane electrode assembly 12 comprises an ion exchange membrane 22 of a solid polymer electrolyte interposed between an anode 24 , and a cathode 26 on a side opposed to the anode 24 . The ion exchange membrane 22 is any ionically conductive and not electron conductive material capable of operating up to 250° C. independent of external humidification, for example, Celtec® membrane electrode assembles from PEMEAS, Inc., preferably between 2 and 8 mils in thickness. The gasket 18 forms an opening 23 wherein the anode 24 is positioned against a side 28 of the end plate 14 and the gasket 20 forms an opening 25 wherein the cathode 26 is positioned against a side 30 of the end plate 16 . The gasket preferably would have a thickness for which a sufficient compression and sealing is achieved.
[0018] Backing plate 13 is positioned adjacent to the end plate 14 and backing plate 15 is positioned adjacent the end plate 16 on opposed ends of the cell (or a stack of cells as described hereinafter). The backing plates 13 , 15 have internal passages for the flow of fuel and an oxidant, respectively, as described hereinafter with reference to FIGS. 6 and 7 . The oxidant preferably comprises air, but could be any gas containing sufficient oxidant for reacting with protons from the anode 24 .
[0019] The backing plates 13 , 15 , end plates 14 , 16 , gaskets 18 , 20 , and ion exchange membrane 12 are held together, for example, by tightening bolts (not shown) inserted through holes 54 formed in opposed corners and secured by nuts (not shown).
[0020] Referring to FIG. 2 , a cross section taken along the line 2 - 2 of FIG. 1 shows the anode 24 and cathode 26 each having a gas diffusion layer 32 and 34 , respectively, comprising carbon cloth, non-woven fabric, or paper of typically between 14 and 16 mils in thickness (z direction), and each have an electrode catalyst layer 36 and 38 , respectively comprising electrocatalysts such as platinum or alloys thereof, of between 10 and 20 microns in thickness (z direction). The material of the gas diffusion layer 32 , 34 is laminated or pressed uniformly on the surface of the electrode catalyst layers 36 , 38 , respectively. The electrode catalyst layers 36 , 38 are affixed to opposite sides of the ion exchange membrane 22 . A plurality of fuel flow channels 40 and a plurality of air flow channels 42 are formed in the end plates 14 and 16 , respectively, and are described subsequently in more detail.
[0021] FIG. 3 is a side view (the view is reversed from that of FIG. 1 ) of the side 28 of plate 14 that is positioned against the anode 24 of the ion exchange membrane 22 . The fuel flow channels 40 comprise a plurality of grooves extending in a serpentine pattern that allows the fuel to flow back and forth across the anode 24 in both the x and y direction. The fuel enters the fuel flow channels 40 at a fuel inlet passage 44 and exits at a fuel outlet passage 46 .
[0022] Referring to FIG. 2 , the fuel diffuses into the gas diffusion layer 32 as it is distributed through the fuel flow channels 40 . Also, the air diffuses into the gas diffusion layer 34 as it is distributed through the air flow channels 42 . Protons from the fuel transverse the electrode catalyst layer 36 , the ion exchange membrane 22 , and the electrode catalyst layer 38 to the gas diffusion layer 34 in a manner known to those in the industry.
[0023] The ideal performance of a fuel cell is defined by its Nernst potential, E, or the ideal cell voltage. The overall reactions for a hydrogen fuel cell is as follows:
Anode: H 2 →2H + +2e −
Cathode: ½O 2 +2H + +2e − →H 2 O
Overall Cell Reaction: H 2 +½O 2 →H 2 O
Nernst Equation: E=E°+(RT/2F) In [P H2 /P H2O ]+(RT/2F) In [P 62 ]
[0024] At the anode, the reaction releases hydrogen ions (protons) and electrons whose transport is crucial to energy production. The protons build up on the anode creating a positive potential which promotes their transfer through the electrolyte (membrane) either by remaining connected through an attraction to a water or phosphoric acid molecule which travels through the electrolyte, or by transferring between water or phosphoric acid molecules. The oxygen side of the water molecule contains a slight negative charge which attracts the protons and may become attached to it, but the attraction is weak so any forces made are easily broken. The actual method of transfer varies depending on the type of electrolyte, but is based on the thickness of the membrane, the amount of water or phosphoric acid in the membrane, and the number of protons transported. Thus, the anode contains a net positive charge while the cathode, towards which the ions drift, contains a negative potential.
[0025] The acid functional groups in the electrolyte serve to provide structure for the electrolyte as well as a barrier to electrons. It is conducive for electrons to flow through materials whose electrons are held loosely (conductive materials) because of the process of electron transport. Thus, electrons move from the reactions sites on the anode through the gas diffusion section of the electrode, through the anode current collector, through a load to do work, across the cathode current collector, through the gas diffusion section of the electrode on the cathode and then to the catalyzed reaction sites on the cathode. The electrons do not move through the electrolyte because the acid chains hold their electrons tightly and thus constitute an electric insulator. Other criteria for selecting an electrolyte are its structural stability, low resistance to ionic movement and low porosity.
[0026] As the fuel is distributed and consumed through the fuel flow channels 40 ( FIG. 3 ), the protons available for conduction to the cathode 26 decrease in number. Just after the fuel first enters the fuel flow channels 40 (at section 70 ), availability of fuel is as high as 95-100%, for example. After the fuel has flowed along the fuel flow channels 40 , the fuel stream would be depleted to as low as 5% fuel availability as the fuel stream exits through the fuel outlet passage 46 (at section 72 ). By forming the serpentine fuel flow channels 40 in the manner shown in FIG. 3 , an even distribution (concentration) of reactant (fuel) of about 50% is created across the anode. By positioning the fuel inlet passage 44 adjacent to the fuel outlet passage 46 , the 100% and 5% proton availability averages out to about 50%. At section 74 , the proton availability of the fuel would be about 75% while the fuel at section 76 would be about 25%, giving an average of about 50-55%. At section 78 the proton availability of the fuel would be about 50% while the fuel at section 80 would be about 50%, giving an average of 50%. The result is a more even distribution of fuel across the anode 24 than previously known.
[0027] FIG. 4 is a side view of the side 30 of the end plate 16 that is positioned against the cathode 26 of the ion exchange membrane 22 . The air flow channels 42 comprise a plurality of short grooves extending in a preferably parallel pattern for allowing oxidizing and cooling gas to flow across the cathode 26 . The air enters the air flow channels 42 at an air inlet passage 66 and exits at a air outlet passage 50 .
[0028] Referring to FIG. 5 , a schematic block view illustrates a stack 52 of fuel cells 10 wherein, except for the cells 10 on the ends of the stack 52 (and more specifically end plates 14 , 16 ), each cell 10 shares a bipolar plate 53 (positioned therebetween) with fuel being distributed on one side and an oxidizing gas being distributed on the other side. In this exemplary embodiment, the cell 10 on one end of the stack 52 has an end plate 14 for distributing fuel that is not shared with an adjacent cell 10 in the stack 52 , and the cell 10 on the other end of the stack 52 has an end plate 16 for distributing the oxidizing gas that is not shared with an adjacent cell 10 in the stack 52 .
[0029] A fuel, such as hydrogen, is fed into the fuel inlet passage 44 at the backing plate 13 , traversing each of the cells 10 in the stack 52 through the fuel inlet passage 44 in the z direction. At end plate 14 and each bipolar plate 53 , some of the fuel is diverted through fuel flow channels 40 to the fuel outlet passage 46 and out of the fuel cell stack 52 at the backing plate 15 .
[0030] Referring to FIGS. 6 and 7 , a cut away view taken along lines 6 - 6 and 7 - 7 of the backing plates 13 , 15 , respectively, are shown. The grooves 58 , 62 and fan groove 64 are internal to the metal backing plates 13 , 15 . An oxidizing agent, such as air preferably, or any gas containing oxidant, is pumped into air inlet passage 48 in backing plate 13 and transverses the stack 52 in the z direction. When the air reaches the backing plate 15 ( FIG. 7 ), the air migrates along groove 58 within the backing plate 15 to oxidation passage 60 and transverses the stack 52 in the −z direction. When the oxidizing agent reaches backing plate 13 again ( FIG. 6 ), it migrates along groove 62 and is dispersed by fan grove 64 to air inlet passage 66 . The oxidizing agent transverses the stack 52 through the air inlet passage 66 in the z direction. When the air reaches bipolar plates 52 and end plate 16 , the oxidizing agent is dispersed through parallel grooves 42 across the cathode 26 . After passing through groves 42 , the air exits through air outlet passage 50 to fan groove 67 and out of the fuel cell 10 through air outlet passage 68 .
[0031] The distribution of air through the air inlet passage 48 in the z direction and then back through the air passage 60 in the −z direction absorbs heat from the cells 10 of the stack 52 . This both cools the stack 52 and preheats the air so the cells first exposed to the air are not cooled significantly more than the rest of the cells. By using the air to cool the stack 52 as well as for cathode oxidant, an additional cooling plate previously used in known fuel cells is avoided.
[0032] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims. | A polymer electrolyte membrane fuel cell stack ( 52 ) includes a plurality of membrane electrode assemblies ( 12 ) having evenly distributed fuel concentration across an anode ( 24 ), and efficient cooling across a cathode ( 26 ). A first plate ( 14 ) has a fuel side ( 28 ) with a plurality of serpentine channels ( 40 ) formed therein for distributing fuel across the anode ( 24 ), and a second plate ( 16 ) has an oxidant side ( 30 ) with oxidant channels ( 42 ) formed therein for distributing an oxidant across the cathode ( 26 ). The membrane electrode assembly ( 12 ) has an even fuel concentration thereacross, and the oxidant is routed through the cell ( 10 ) at least twice for absorbing heat prior to being distributed across the cathode ( 26 ). | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. Ser. No. 10/893,615, filed on Jul. 16, 2004, now pending, which claims priority from Korean Patent Application No. 2003-48652, filed on Jul. 16, 2003, all of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a printed circuit board (PCB) for manufacturing a semiconductor package, and more particularly, to a thin PCB for manufacturing a chip scale package (CSP).
[0004] 2. Description of the Related Art
[0005] In recent years, as most electronic products including various portable data communication devices, such as personal computers, cellular phones, and personal data terminals, have been scaled down and become more light-weight and efficient, their data processing capacities have increased. Thus, using a chip scale package (CSP) technique, a semiconductor chip can be assembled in a semiconductor package having a size similar to or slightly larger than the chip size. CSP techniques vary according to manufacturing methods, for example, a thin PCB method of manufacturing a CSP. In this method, semiconductor packages comprise a semiconductor chip manufactured with a thin PCB. However, the thickness (e.g., 0.17 mm or less) of a conventional thin PCB for manufacturing a CSP is typically smaller than that (e.g., 3 mm) of a conventional PCB for manufacturing a typical semiconductor package.
[0006] FIGS. 1 through 3 are diagrams illustrating problems of a conventional thin PCB. As shown in FIG. 1 , in a conventional thin PCB 10 , a plurality of unit PCBs 10 a , 10 b , and 10 c are connected in a row. Although only three exemplary unit PCBs 10 a , 10 b , and 11 c are illustrated in FIG. 1 , the thin PCB 10 can include a greater number of unit PCBs. Circuit patterns 11 a , 11 b , and 11 c are disposed in the unit PCBs 10 a , 10 b , and 10 c , respectively. A plurality of holes (not shown) are formed in each of the circuit patterns 11 a , 11 b , and 11 c . A plurality of holes or slots 12 are vertically arranged at interfaces between adjacent unit PCBs, for example, between the unit PCBs 10 a and 10 b or 10 b and 10 c . These holes or slots 12 suppress distortion of the PCB 10 . A plurality of holes 13 are formed in an upper portion of the thin PCB 10 , and a plurality of holes 14 are formed in a lower portion thereof. These holes 13 and 14 are used as recognition marks for a package manufacturing apparatus and may be used for alignment of the thin PCB 10 when the thin PCB 10 is transferred.
[0007] As described above, the thin PCB 10 has a relatively small thickness. Thus, the thin PCB 10 is flexible and makes it difficult to manufacture semiconductor packages. Thus, one solution shown in FIG. 2 was proposed. That is, semiconductor packages are manufactured using a carrier 20 supporting a thin PCB 10 . In this method, since the thin PCB 10 is supported by the carrier 20 , it is inflexible during package manufacturing processes. The carrier 20 can be formed of an inflexible material, for example, a sus material. A vacant space 23 is located in the center of the carrier 20 so as to expose the rear surface of the thin PCB 10 . The carrier 20 is a kind of frame that surrounds the vacant space 23 . Holes 21 are formed on both lateral surfaces of the carrier 20 , and a mark 22 is formed on an edge thereof. The holes 21 and the mark 22 are used as recognition marks and may be used for alignment of the carrier 20 when the carrier 20 is transferred.
[0008] As shown in FIG. 3 , in order to adhere the thin PCB 10 to the carrier 20 , the thin PCB 10 is first mounted on the carrier 20 . Only the upper and lower portions of the thin PCB 10 overlap upper and lower portions of the carrier 20 and are supported by the carrier 20 , and the remaining portion of the thin PCB 10 do not overlap the carrier 20 . Next, the thin PCB 10 is secured to the carrier 20 by an adhesive 31 . The adhesive 31 is applied to the upper and lower portions of the thin PCB 10 and the upper and lower portions of the carrier 20 .
[0009] As described above, since the conventional thin PCB 10 has a very small thickness, it should be adhered to a supporting portion such as the carrier 10 and used in package manufacturing processes. Thus, prior to the package manufacturing processes, additional processes of aligning and adhering the thin PCB 10 to the carrier 20 should be performed. Also, after a semiconductor package is completed, a process of removing the adhesive 31 from the carrier 20 should be further performed to reuse the carrier 20 .
SUMMARY OF THE INVENTION
[0010] The present invention provides a thin printed circuit board (PCB) that is inflexible during package manufacturing processes, despite its very small thickness.
[0011] According to an aspect of the present invention, there is provided a thin printed circuit board for manufacturing a chip scale package. The thin printed circuit board comprises a plurality of unit printed circuit boards which each adhere to a semiconductor chip, and a substrate surrounding the circuit pattern. Each unit printed circuit board comprises a circuit pattern. The unit printed boards are arranged in a row. The thin printed circuit board comprises a support molding, which is spaced a predetermined interval apart from the circuit pattern of each unit printed circuit board on the substrate of each unit printed circuit board and formed in a ring shape along the edge of the thin printed circuit board.
[0012] The support molding may comprise epoxy molding compound or resin.
[0013] The support molding can be formed using a metal pattern.
[0014] One or more holes or slots can be vertically arranged at interfaces between adjacent unit printed circuit boards to prevent distortion of the thin printed circuit board.
[0015] According to another aspect of the present invention, there is provided a thin printed circuit board for manufacturing a chip scale package. The thin printed circuit board comprises a plurality of unit printed circuit boards, each of which comprises a circuit pattern, to which a semiconductor chip is adhered, and a substrate surrounding the circuit pattern. The unit printed boards may be arranged in a row. The thin printed circuit board comprises one or more slots, which are vertically arranged at interfaces between the unit printed circuit boards; and support moldings, which are spaced apart from the circuit patterns of the unit printed circuit boards above and below the interfaces between the unit printed circuit boards and formed perpendicular to the direction in which the slots are formed.
[0016] The support moldings can be formed of one of an epoxy molding compound and a resin.
[0017] The support moldings can be formed using a metal pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0019] FIGS. 1 through 3 are diagrams illustrating a conventional thin PCB;
[0020] FIG. 4 is a diagram illustrating a thin PCB according to an embodiment of the present invention; and
[0021] FIG. 5 is a diagram illustrating a thin PCB according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention will now be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein.
[0023] FIG. 4 is a diagram illustrating a thin PCB according to an embodiment of the present invention.
[0024] Referring to FIG. 4 , a thin PCB 400 of the present embodiment comprises a plurality of unit PCBs 400 a , 400 b , and 400 c , which are connected in a row. Although only three exemplary unit PCBs 400 a , 400 b , and 400 c are illustrated in FIG. 4 , the thin PCB 400 can include a greater number of unit PCBs. Circuit patterns 410 a , 410 b , and 410 c are formed in the unit PCBs 400 a , 400 b , and 400 c , respectively. A plurality of holes (not shown) are formed in each of the circuit patterns 410 a , 410 b , and 410 c . A semiconductor chip is adhered to each of the circuit patterns 410 a , 410 b , and 410 c in a subsequent process, and a signal is transmitted from the semiconductor chip through the holes formed in the circuit pattern 410 a , 410 b , or 410 c out of the package. A plurality of holes or slots 420 are vertically arranged at interfaces between adjacent unit PCBs, for example, between the unit PCBs 410 a and 410 b or 410 b and 410 c . These holes or slots 420 suppress distortion of the thin PCB 400 . A plurality of holes 430 are formed in an upper portion of the thin PCB 400 , and a plurality of holes 440 are formed in a lower portion thereof. These holes 430 and 440 are used as recognition marks for a package manufacturing apparatus and may be used for alignment of the thin PCB 400 during thin PCB 400 transfer.
[0025] A support molding 450 is formed along the edge of the thin PCB 400 . In the present embodiment the support molding 450 is formed of an epoxy molding compound (EMC) or a resin and formed using a metal pattern. The support molding 450 may be formed in a ring shape along the edge of the thin PCB 400 and spaced apart from the circuit patterns 410 a , 410 b , and 410 c . That is, the support molding 450 may not contact the circuit patterns 410 a , 410 b , and 410 c . The support molding 450 can support the circumference of the thin PCB 400 . Thus, the thin PCB 400 can be inflexible during package manufacturing processes despite its very small thickness.
[0026] FIG. 5 is a diagram illustrating a thin PCB according to another embodiment of the present invention.
[0027] Referring to FIG. 5 , the thin PCB 500 of the present embodiment comprises a plurality of unit PCBs 500 a , 500 b , and 500 c , which are connected in a row. Although only three exemplary unit PCBs 500 a , 500 b , and 500 c are illustrated in FIG. 5 , the thin PCB 500 can include a greater number of unit PCBs. Circuit patterns 510 a , 510 b , and 510 c are formed in the unit PCBs 500 a , 500 b , and 500 c , respectively. A plurality of holes (not shown) are formed in each of the circuit patterns 510 a , 510 b , and 510 c . A semiconductor chip is adhered to each of the circuit patterns 510 a , 510 b , and 510 c in a subsequent process, and a signal is transmitted from the semiconductor chip through the holes formed in the circuit pattern 510 a , 510 b , or 510 c out of the package. A plurality of holes or slots 520 are vertically arranged at interfaces between adjacent unit PCBs, for example, between the unit PCBs 510 a and 510 b or 510 b and 510 c . These holes or slots 520 suppress distortion of the thin PCB 500 . A plurality of holes 530 are formed in an upper portion of the thin PCB 500 , and a plurality of holes 540 are formed in a lower portion thereof. These holes 530 and 540 are used as recognition marks for a package manufacturing apparatus and may be used for alignment of the thin PCB 500 during thin PCB 500 transfer.
[0028] In the thin PCB 500 , portions where the slots 520 are formed are most vulnerable to external force and flexible. Thus, support moldings 551 and 552 may be formed above and below the interface between adjacent unit PCBs 500 a , 500 b , and 500 c , that is, above and below the portions where the slots 520 are formed. Although the slots 520 are formed vertically, the support moldings 551 and 552 may be formed horizontally, i.e., substantially perpendicular to the direction in which the slots 520 are arranged. As in the first embodiment, the support moldings 551 and 552 may not contact any of the circuit patterns 510 a , 510 b , and 510 c . In the present embodiment the support moldings 551 and 552 are formed of an EMC or a resin and can be formed using a metal pattern. In the present embodiment, the support moldings 551 and 552 can support the interfaces between the unit PCBs 500 a , 500 b , and 500 c , which are the most vulnerable portions of the thin PCB 500 . Thus, the thin PCB 500 can be inflexible during package manufacturing processes despite its very small thickness.
[0029] As explained thus far, a thin PCB for manufacturing a chip scale package (CSP) according to the present invention comprises a support molding formed along the edge of the thin PCB or a plurality of support moldings formed above and below interfaces between unit PCBs, which are vulnerable to external force. Thus, the thin PCB can be inflexible during package manufacturing processes despite its very thin thickness. Accordingly, the manufacture of semiconductor packages can be simple without using an additional supporting portion.
[0030] While the present invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. For example, the present invention is not limited to thin PCBs. Of course, other various thin substrates for CSPs, for example, polyimide tape substrates, can be used and include support moldings in the same manner as the thin PCBs.
[0031] Although the exemplary embodiments of the present invention have been described in detail, it should be understood that many variations and/or modifications of the basic inventive concepts herein taught, which may appear to those skilled in the art, will still fall within the spirit and scope of the present invention as defined in the appended claims. | Provided is a thin printed circuit board (PCB) for manufacturing a chip scale package (CSP). The thin printed circuit board includes a plurality of unit printed circuit boards, each of which is comprised of a circuit pattern, to which a semiconductor chip is adhered, and a substrate surrounding the circuit pattern. The unit printed boards are arranged in a row and includes a support molding, which is spaced a predetermined interval apart from the circuit pattern of each unit printed circuit board on the substrate of each unit printed circuit board and formed in a ring shape along the edge of the thin printed circuit board. | 7 |
BRIEF DESCRIPTION OF THE PRIOR ART
It is well known in the patented prior art -- as evidenced, for example, by the prior Sullivan U.S. Pat. Nos. 2,778,917, 2,871,317 and 3,140,721 -- to provide temperature and/or pressure responsive actuator means for operating load devices (such as the shut-off valves connected in the fuel supply lines to steam boilers and the like).
One drawback of the known devices is their failure to detect or respond to dangerous ambient conditions external of the vessel chamber. Thus, in the event of a fire in the boiler room of a building heated by the boiler means, the possibility exists of ignition of the fuel supplied to the boiler and a resulting dangerous explosion.
SUMMARY OF THE INVENTION
Accordingly, the present invention was developed to provide control means for a boiler or the like including actuator means for interrupting the flow of combustible gas to the boiler in the event that boiler pressure and/or temperature exceed predetermined limits, or the temperature external to the boiler exceeds a predetermined limit.
A primary object of the present invention is to provide actuator means for operating a load device including a pressure-responsive assembly mounted for axial displacement relative to an opening contained in a pressure vessel, such as a boiler, said pressure assembly including a tubular member which is closed at one end to define a probe that extends into the vessel chamber. A rod is arranged coaxially in the tubular member and is secured at one end to the closed probe end by first fusible means. At its other end, the rod is connected with a load operating member by second fusible means. First spring means bias the tubular member away from the load device, and second spring means bias the operating member toward the load device. Consequently, when the pressure in the vessel exceeds a predetermined limit, the pressure assembly is shifted against the biasing force of the first spring means to operate the load device. If the temperature within the vessel exceeds a predetermined limit, the first fusible means melts to release the rod, whereby the rod and the load operating member are displaced by the second spring means to operate the load device. In accordance with a characterizing feature of the present invention, if the temperature external of the vessel exceeds a predetermined limit, the second fusible means melts to release the load operating member, whereby the load operating member is displaced toward the load device by the second spring means.
According to another object of the invention, the actuator means serves to control the operation of a shut-off valve which in turn controls the supply of fuel to the vessel (specifically, a gas- or oil-fired boiler). The load device, which is normally supported on a ledge, is connected with the shut-off valve to normally maintain the same in an open condition. When the load device is actuated by the actuator means, the load device is displaced from its supporting ledge and the shut-off valve is operated to the closed condition to interrupt the supply of fuel to the vessel. In accordance with another feature of the invention, the means which connects the load device with the shut-off valve means includes third fusible means responsive to the ambient temperature external of the vessel.
According to a further feature of the invention, solenoid means may also be provided for operating the load device to close the shut-off valve means.
BRIEF DESCRIPTION OF THE DRAWING
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in the light of the accompanying drawing, in which:
FIG. 1 is a longitudinal sectional view of the actuator means of the present invention connected with shut-off valve means;
FIGS. 2 and 3 are detailed views of the probe means with the fusible means in the non-melted and melted conditions, respectively;
FIG. 4 illustrates the operation of the load device by the load operating member when the fusible means at the probe end (FIG. 2) has melted to release the rod member;
FIG. 5 is a sectional view illustrating the operation of the load device by the temperature and pressure-responsive assembly when the pressure in the vessel exceeds a predetermined limit;
FIG. 6 illustrates the operation of the load device by the operating member when the fusible connection between the rod and the load operating member has melted to release the load operating member;
FIG. 7 illustrates the provision of auxiliary solenoid means which may be used in conjunction with the actuator means of FIG. 1 for operating the load device;
FIG. 8 is a detailed schematic diagram of the electrical circuitry associated with the auxiliary switch means of FIG. 1; and
FIGS. 9 and 10 illustrate boiler and furnace installations, respectively, including the control means of the present invention.
DETAILED DESCRIPTION
Referring first more particularly to FIG. 1, the actuator means of the present invention is adapted for connection with the wall opening 5 of a vessel 1, which, in the illustrated embodiment, comprises an oil- or gas-fired boiler.
The actuator means comprises a hollow support member 7 which contains a longitudinally movable pressure and temperature responsive assembly 27. The support means comprise a hollow body which contains a first pressure chamber 9. A first wall portion 11 at one end of the body 8 contains a first opening 13. A pipe nipple 15 connects the chamber 3 and the first pressure chamber 9 via openings 5 and 13.
Pet cock sediment drain means 16 is provided for draining accumulated moisture from the device and for testing the pressure sensing mechanism of the actuator.
A second wall portion 17 at the opposed end of the support body 8 includes a brass plate 18 and contiguous spacer block 19 containing a threaded bore 20. A bushing 21 adjustably threaded within the bore 20 contains a centrally disposed bore which defines a second opening 23 in the support means 7. The hollow body member 8 is connected with the brass plate 18 by bolts 25.
The pressure- and temperature-responsive assembly 27 comprises a tubular member 29 which terminates at one end in a closed end portion 31 defining a temperature probe disposed within the vessel chamber 3. The tubular member 29 extends from chamber 3 completely through the hollow support means 7 and terminates in an open end portion 33 beyond the second opening 23.
Expansible pressure responsive means 35 in the form of a bellows is disposed within the first pressure chamber 9 so as to define a second pressure chamber 37 which communicates with the ambient atmosphere within control panel 41 via second opening 23. One end 43 of the bellows 35 is peripherally disposed about threaded bore 20 and is secured to the stationary brass plate 18. The opposite end of the bellows is attached to a movable hollow guide piston 45 which is concentrically threadably mounted upon a hollow rod 46 through which tubular member 29 extends. Rod 46 extends through the bellows 35 and bore 23 into the housing 41. A plurality of flats 47 are formed in chamber 9 adjacent the guide piston 45, which flats mate with similar flats on piston 45 to prevent rotation of piston 45 and twisting of bellows 35. A first spring means, in the form of a compressions spring 53, is disposed in the bellows 35 about hollow rod 46 so that one end of spring 53 engages a recess 54 in the threaded bushing 21. The opposed end of spring 53 engages the movable end of the bellows and tends to expand the bellows toward the chamber 3. The bushing 21 may be adjusted to vary the compression of spring 53 and thus the external pressure force required to compress it.
A rod 61 is disposed within the tubular member 29, one end 63 of said rod terminating in the probe end 31 of the tubular member 29, while the other end 64 extends beyond the open end 33 of the tubular member 29. The rod end 63 is normally retained in probe end 31 by a first temperature-responsive fusible means 67 in the form of a body of temperature calibrated solder. A plurality of spaced projections 68 are provided on the rod end 63 to hinder undesired migration of the solder. Similar projections are also placed on the interior surface of the probe end of tubular member 29 for the same purpose.
A cap 69 having an aperture therein is connected with the end of hollow rod 46 which extends into housing 41. Rod 61 extends through the aperture of the cap to a load operating member 70 disposed adjacent the cap. The load operating member contains first and second recesses 71 and 72 on opposite sides of a wall 73. Wall 73 has an aperture therein to provide communication between the recesses. Trigger rod 61 extends through both the first recess 71 and the aperture in wall 73 and terminates at its end 64 in the second recess 72. A second temperature responsive fusible means 74 in the form of a body of temperature calibrated solder is disposed in the second recess 72 and normally retains the rod end 64 within the second recess 72. The first recess 71 is dimensioned to receive the cap 69. A second spring means 77 in the form of a compression spring is disposed within recess 71 and acts between the wall 73 and the cap 69 to bias the operating member 70 away from the cap and also to bias the trigger rod away from the probe end 31 of the tubular member 29.
The pressure and temperature responsive assembly 27 is disposed in operative relation with fluid flow control means to control the flow of a fluid from a source of supply to chamber 3. More particularly, the control means comprises a trigger member 83 disposed within the housing 41 adjacent the normal position of the operating member 70 and supported by a ledge 85 which permits displacement of the trigger member therefrom. An elongate member 87 suspended from one end of the trigger member 83 extends from the housing 41 through a conduit shown generally at 89 to a valve member 91 disposed in a fluid supply conduit 93. The valve member 91 is biased towards a closed position with respect to conduit 93 by a compression spring 95. Valve member 91 is maintained in a normally open position against the action of spring 95 when the trigger member 83 is supported on the ledge 85. Displacement of the trigger member 83 from the ledge 85 by the actuator means effects downward movement of the valve member to the closed position.
The elongate member 87 includes a temperature responsive fusible link 97 which is positioned in a portion 99 of the conduit 89 which provides direct access to the ambient atmosphere. Should link 97 be subjected to an ambient temperature exceeding a predetermined limit, the link will melt, thereby separating the elongate member 89 and permitting the valve member to close.
OPERATION
In the operation of this embodiment, the valve member 91 is closed in response to any one of several conditions--namely, either the temperature or pressure within the chamber 3 exceeding predetermined limits, the temperature within the panel housing 41 exceeding a predetermined limit, or the temperature of the ambient atmosphere adjacent the boiler exceeding a predetermined limit.
FIG. 2 illustrates the rod 61 normally at the probe end 31 within the tubular member 29 prior to the occurence of an excessive temperature or pressure within the chamber 3. Upon excessive temperature being reached within the chamber 3, the first temperature responsive fusible means 67 will melt (FIG. 3) and thus free the rod 61 for movement from the probe end 31 of tubular member 29. With trigger rod 61 no longer restrained by fusible means 67, the spring 77 forces the operating member to displace the member 83 from ledge 85 as shown in FIG. 4. The valve member 91 will thus no longer be supported and will be closed by the action of spring 95.
FIG. 5 illustrates the actuator after it has been subjected to an excessive pressure in the chamber 3. As the pressure in the chamber 3, and, consequently, in the first pressure chamber 9, exceeds a predetermined limit established by spring 53, the entire pressure- and temperature-responsive assembly is moved away from the chamber 3 in a first direction toward the device 83, thereby displacing the member 83 off of the ledge to effect valve closure. More specifically, the excessive pressure in chamber 9 causes the bellows 35 to be compressed against the action of spring 53. The guide piston 45 is moved with the bellows 35 toward the second opening 23 while the hollow rod 46, tubular member 29, and trigger rod 61 are moved through the opening 23. The plug 69, spring 77 and operating member 70 will be carried along by this movement whereby operating member 70 will displace load device 83 from ledge 85.
Upon the occurrence of an excessive temperature condition within the panel housing 41, the second temperature-responsive fusible means melts to release the trigger rod end 64, whereupon the spring 77 causes the operating member 70 to displace the device 83 from the ledge (FIG. 6) and thereby effect valve closure.
In the event that the temperature of the ambient atmosphere outside the container wall 1 exceeds a predetermined temperature, the fusible link 97, in direct communication with the atmosphere via conduit portion 99, melts, thus separating the elongate member 87 and permitting the valve member 91 to close the conduit 93.
Referring now to FIG. 7, the apparatus of FIG. 1 may also be provided with auxiliary solenoid means 100 having an armature 101 arranged to displace the load device from its support ledge 85 to close the shut-off valve means as described above. The solenoid means may be operated by suitable switch means (such as a manually operated switch, not shown).
Referring now to FIG. 8, switch means 104 is mounted within the housing 41 for operation by the load operating member 70. The switch means includes a first pair of normally closed contacts 104a connected to the alarm means 108, a second pair of normally open contacts 104b connected with ground, and a third pair of normally open contacts connected with the normally closed burner valve means 110 of the boiler via manual switch 112. The switch means also includes an operating member 105 that is normally maintained in the illustrated first position by the load operating member 70 to open the circuit to alarm means 108, and to close the circuits to ground and to the burner valve means 110. When the operating member 70 is displaced to the right to displace the load member 83 from ledge 85, switch operating member 105 is released to close the alarm circuit and to open the circuit to ground and to the burner valve means 110.
The pressure and/or temperature responsive control means of the instant invention has utility in various types of installations, as shown nin FIGS. 9 and 10. For example, in the boiler installation of FIG. 9, the controller may be utilized to control the water supply valve 93 to the boiler, a normally-closed solenoid valve 120 also being connected in the water supply line. The solenoid valve 120 is so connected with the electric switch means 140 that when the output member 70 is in the FIG. 8 position, solenoid valve 120 is energized and maintained open, and shut-off valve 93 is maintained open by the mechanical linkage 87. Fuel is supplied to the burner 122 via solenoid valve 124 which is normally maintained open by suitable pressure and/or temperature responsive switch means (such as the control means of my prior U.S. Pat. No. 2,871,317, for example).
Similarly, in the gas or oil-fired furnace arrangement of FIG. 10, the shut-off valve 93 and the solenoid valve 120 may be connected in the fuel supply line to the furnace burner.
While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various modifications may be made in the apparatus described and illustrated without deviating from the inventive concepts set forth above. | Actuator means of the pressure- and/or temperature-responsive type are disclosed for controlling valve means which supply pressure fluid (such as a combustible gas) to a load (such as a gas-fired boiler), characterized in that the actuator means are operable (1) when the boiler pressure exceeds a given limit, (2) when the boiler temperature exceeds a given limit, or (3) when the temperature a given region external of the boiler exceeds a given limit. The valve means is normally in an open condition, said actuator means being operable to close the valve means when at least one of the aforementioned limits is exceeded. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an improved composite histologic tissue receptacle and embedding structure which serves as an integral, perforate, shallow depth, receptacle for holding tissue during the processing thereof, as a mold for embedding processed tissue in a paraffin body preparatory to mounting in the microtome, as a means for aligning and holding the embedded specimen in the microtome and as a receptacle for protecting and storing the embedded tissue after portions of the same have been severed by the microtome.
2. Description of the Prior Art
A composite tissue receptacle and embedding structure of the type most closely related to this invention is taught by U.S. Pat. No. 3,456,300. The structure taught by this patent includes an open mold, a base pan which is detachably secured onto either open end of the open mold and a perforated top which is detachably secured onto the other end of the open mold all of which forms an integral closure for the specimen. The open mold element of the patent is rectangular in cross section and includes four smooth surfaced perpendicular and interconnecting walls. An outer surface of the upper mold is etched in order to receive indicia by means of an ordinary pencil. The base pan of the patent is shaped substantially like a rectangular open topped box with a thin, heat conducting, flat bottom surface and an indented ledge which extends downwardly from the inside edge of the base pan walls so as to "snap fit" onto either end of the open mold. The flat bottom surface is provided with openings which allow the processing fluids to pass through the composite tissue embedding structure. The perforated top of the patent is detachably secured to the other end of the open mold and consists of a perforated rectangular shaped surface having outwardly projecting sides which "snap fit" over the end of the open mold. The top element in conjunction with the mold and pan elements of the patent forms an integral perforate structure which can be inverted, tilted and otherwise handled without coming apart.
Since the device of the present invention specifically improves on the device of the U.S. Pat. No. 3,456,300, the operation of the device of the patent will next be explained to more fully appreciate the prior art. In operation, a tissue specimen to be pathologically examined is placed in the base pan of the prior patent device without regard to any particular position. One end of the open mold is "snap fastened" to the base pan and the other end of the mold is "snap fastened" to the perforated top to provide the mentioned integral, perforate enclosure for the specimen. The serial number of the tissue specimen is marked by means of a graphite pencil onto an etched surface of the open mold. The mold with the top cover and base pan "snap fastened" to it at either end at this stage provides a perforate tissue processing receptacle. The composite tissue embedding structure is placed sequentially into various treating liquids and finally into a paraffin bath where paraffin is transferred by osmosis into the tissue cells.
As the description proceeds, many similarities will be observed between the construction and use of the device of the U.S. Pat. No. 3,456,300 and the present invention. However, what is important to observe is that the patent device makes no provision for telescoping the pan section into the mold section for reducing the amount of space occupied during processing when the three elements form a processing receptacle. With an increasing use of the patent device the need to process greater and greater numbers of receptacles in the processing chambers has become increasingly critical and important. The relative depth of the three elements when assembled as a processing receptacle thus becomes of increasing importance since this depth to a major extent determines how many receptacles can be processed simultantously. The bottom outside surface is next wiped to remove excess paraffin. At this stage, a thin film of paraffin coats the bottom inside surface of the boat receptacle and while the paraffin is hot and tacky, the perforated top is removed and may be discarded as a disposable item. After adding additional liquid paraffin, the specimen is repositioned on the flat bottom surface of the base pan into a precise cutting position. The paraffin is allowed to harden so that the precise plane of the specimen along which it is to be severed is presented to the microtome blade. The positioning of the specimen is most important for frequently the only means for determining the malignancy of tissue is by properly selecting the plane of severance. As an alternative, the thin coating of paraffin clinging to the bottom surface of the boat receptacle may be allowed to harden and later reheated and the tissue specimen repositioned. In either case, the tissue specimen is positioned while the mold and base pan are "snap fastened" together.
After the tissue specimen is selectively positioned in the base pan, melted paraffin is poured into the base pan through the open end of the open mold to a level substantially adjacent that open end thus completely embedding the tissue specimen. After the paraffin hardens and approaches room temperature, the tissue specimen is presented to the blade of the microtome. Thus, while the base pan remains "snap fastened" to the mold, the composite structure is placed in the jaws of the microtome with the jaws abuted against the exposed surface of the edges of the base pan which act to align the cutting surface of the paraffin block with the microtome blade. After such alignment, the jaws of the microtome are tightened onto the open mold and the base pan is removed which exposes the bottom surface of the block for cutting. After one or several sections are sliced from the tissue specimen by the microtome knife, the base pan is "snap fastened" back onto the open mold so as to cover the exposed tissue specimen surface and prevent the same from becoming soiled or damaged during the usual extended storage for possible later reference to the same patient. At any later time, the tissue specimen may be removed from storage and made available for further sectioning and in the interim the base pan acts as a protective cover.
Further prior art includes devices for processing tissue in plastic or metal perforated containers and for embedding the tissue with paraffin in separate plastic, paper, or metal pans. The device of U.S. Pat. No. 3,674,396, for example, uses a perforated plastic container with a removable metal perforated cover for processing. This metal cover is removed after processing and the tissue specimen is transferred to a metal pan for embedding. The container is then placed in the metal pan and the unit is filled with paraffin for embedding. These devices offer some advantage in providing a relatively shallow depth receptacle for processing but lack the advantage of being able to use the same device for all the steps of processing, embedding, slicing and storing. The devices referred to in U.S. Pat. No. 3,456,300 and in a prior U.S. Pat. No. 2,996,762 mark an advancement over this latter type art since it is desirable to provide an identification mold section which can be used through tissue processing with a perforated top and a pan section, as one unit, for holding and transporting the tissue specimen through the various processing liquids, then as a mold for paraffin embedding the specimen and as a holder for holding the embedded specimen in a microtome during slicing and as a cover for protecting the remaining paraffin tissue block during storage.
Thus, while it can be said that the prior art device described in U.S. Pat. No. 3,456,300 represented a substantial improvement over other prior art devices, there has remained a substantial need to retain the multi-purpose advantages of the patent device but to reduce the amount of space required to process embedded specimens. Stated differently, larger and larger quantities of tissue specimens are being embedded in hospitals, pathology laboratories, and the like, which means that while the device of U.S. Pat. No. 3,456,300 has vastly improved the processing, embedding, and slicing procedures there still remains an critical problem of processing embedded specimens in a minimum of space.
SUMMARY OF THE INVENTION
The compact telescoping tissue processing and embedding receptacle of the invention is comprised of a mold opening at both its top and bottom ends, hereafter known as the identification mold; a pan section which may either be detachably secured to the bottom of the identification mold for molding purposes or fitted downward through the top of the identification mold thereby telescoping within the identification mold during processing for reducing the receptacle depth and a perforated over or top section which encloses both the identification mold and pan telescoped within by means of two appended sidewalls which extend perpendicularly downward from the ends of the perforated top and overlap the outer end walls of the identification mold to a point where these overlapping sidewalls turn perpendicularly inward to form sliding tongue members which operate in grooves that are cut along the outer end walls of the identification mold. The tongue and grooves extend for only a portion of the length of the respective walls in which they are formed which gives the top section a positive stop in one direction and adds to its positive securement. The top sidewalls and mold walls could be otherwise formed so long as the top member can be detachably secured to the mold member.
After the pan section has been telescoped into the mold section and the top section slid into place, the three sections act together to form a perforated enclosure, hereafter called the processing unit, for the tissue specimen. Each element or section may be molded of the same kind of material so long as such material is moldable and inert to the various processing fluids. The exterior surfaces of the sidewalls of the mold section are smooth and provide surfaces to receive indicia by means of an ordinary pencil.
The interior wall surfaces of the identification mold are preferably sloped inwardly at an approximate angle of 03° off vertical which sufficiently increases the thickness of the walls near the bottom to allow the exterior sides of the end walls to be grooved as previously mentioned. The interior and exterior wall surfaces of the identification mold are preferably smooth and uninterrupted by projections, flanges, or the like. However, a narrow and continuous ledge extends inward from the bottom edges of each interior wall of the mold section at an angle of approximately 93° and acts both as a resting shelf for the telescoped pan during processing and as a trapping or gripping member for the hardened paraffin during microtome cutting. The wall surfaces of the mold are otherwise free of flanges, projections, or the like, which minimizes opportunity for tissue damage and enhances opportunity to observe and position the tissue. While the described ledge offers minimum interference and has been found useful to secure the molded block, it is contemplated that the mold interior wall surfaces could be otherwise formed to secure the block. For example, two converging, angled interior walls could be used as in FIG. 7 of U.S. Pat. No. 3,456,300.
The outside width and length of the open mold are preferably limited to about one and five-eighths inches long by one and one-sixteenth inches wide and with a depth of about one-fourth of an inch. The pan section is shaped substantially like an open topped rectangular box composed of four interconnecting walls, a thin heat conducting flat bottom surface, and has a continuous ledge which extends outward from the top edge of each exterior wall. Both exterior and interior walls of the pan section are smooth, uninterrupted and sloped at an angle from top to bottom which corresponds to the slope of the mold walls and allows the pan to telescope within the identification mold as a primary step in the assembly of the processing unit.
The pan ledge which extends outward from the top edges of the exterior walls serves three purposes. During processing, when the pan is telescoped within the identification mold, the ledge provides a positive stop and deters the pan from falling through the mold since it overlaps the top edges of the mold. During embedding, when the pan is positioned underneath the identification mold, the pan ledge acts as a base on which the bottom edges of the walls of the identification mold may rest and be snap-fitted to the pan section. At the same time, the identification mold is prevented from shifting its position on the pan ledge by means of a small, continuous lip which provides the snap-fit and extends perpendicularly upward from the outside edges of the pan ledge to surround a small area of the lower exterior walls of the identification mold. The securing lip also serves to eliminate the need for aligning flanges on the identification mold during microtome cutting since the pan lip furnishes a means of obtaining alignment of the paraffin block with the microtome jaws. The third purpose served by the pan ledge is that of acting as an aid for handling the pan throughout the various steps of processing and embedding. After embedding and following the slicing of the tissue block by the microtome, the pan has the additional function of serving as a protective cover for the exposed block since the pan may, at any time, be resecured to the identification mold.
In order to assemble the processing unit, the pan section is first telescoped into the identification mold. Following that, the sliding tongue members of the top section are inserted into the open ends of the identification mold grooves and the top section is then pushed forward, its enclosing sidewalls moving along the outside end edges of the pan ledge while the sliding tongue members move along inside the grooves of the identification mold. When the sliding members have been pushed as far as possible into the grooves, the perforated top completely covers the open pan so that the side edges of the top are flush with the side edges of the pan ledge and an integral, perforate processing unit is thereby created. The width and length of the processing unit are preferably limited to about one and one-eighth inches wide and one and thirteen-sixteenths inches long with the depth of the same being about thirteen thirty-seconds of an inch. The depth of the device of the invention when used as a processing unit thus constitutes a major improvement over that taught by U.S. Pat. no. 3,456,300, the depth of which is twice that of the invention. Accordingly, substantially more specimens may be processed in a given space than with the device of the patent.
In use, the specimen accession number is written on one etched surface of the exterior walls of the identification mold. The tissue which is to be pathologically examined is placed in the pan section without regard to any particular position and the perforated top section is slid into place as previously explained. The processing unit thus created is capable of serving all purposes conventionally served by the processing receptacle taught by U.S. Pat. No. 3,456,300, yet the depth or thickness of the invention remains one-half that of the prior art. A plurality of processing units are then stacked side-by-side in a tissue processing basket which in turn is placed in an automatic tissue processor where the specimens undergo exposure to various liquids such as alcohol and xylene which prevent autolization and prepare the specimen for embedding. As a final step within the processor, the specimens are bathed in liquid paraffin whereupon quantities of paraffin are transferred by osmosis into the tissue cells as previously explained. The basket is then removed from the processor and the receptacle units are removed and placed on a heated surface. The top section is removed from each unit by sliding the tongue members backwards out of the grooves. The heretofor processing unit now becomes the embedding unit as the relative positions of the pan and the identification mold are reversed. This is accomplished by removing the pan from its telescoped positioned within the mold and then placing the mold on top of the pan where it rests on the pan ledge and is snugly held in place by the surrounding lip which extends upward from the ledge. This embedding unit is then partially filled with melted paraffin and placed on a cold surface. As the paraffin begins to solidify, the tissue specimen is respositioned into a precise cutting position. The paraffin is allowed to harden so that the precise plane of the specimen along which it is to be severed is presented to the microtome blade. The positioning of the specimen is most important, as previously explained, for frequently the only means for determining the malignancy of tissue is by properly selecting the plane of severance. As an alternative, the paraffin which partially fills the pan may be allowed to harden and at a later time may be reheated and the tissue specimen repositioned. In either case, the tissue specimen may be positioned while the identification mold is securely resting upon the pan ledge since the mold itself is free of internal projections which might otherwise interfere with such repositioning.
After the tissue specimen has been selectively positioned in the pan, melted paraffin is poured into the pan through the open end of the identification mold to a level which is substantially adjacent that open end thus completely embedding the tissue specimen after accounting for the shrinkage of the paraffin upon solidification. The paraffin is allowed to cool and the cooling may be hastened by placing the pan and identification mold on a cold surface. After the paraffin has hardened and been cooled with ice, or otherwise, the tissue specimen is adapted to be presented to the blade of the microtome. Thus, while the identification mold remains snap-fit secured to the pan ledge, the composite structure is placed in the jaws of the microtome whereby the jaws abut against the securing lip of the pan ledge which acts to align the cutting surface of the paraffin block with the microtome blade.
After such alignment, the jaws of the microtome are tightened onto the identification mold and the pan is removed. The tissue block at this stage is prevented from being pulled from the mold by the gripping effect of the internal identification mold ledge and the removal of the pan exposes the bottom surface of the block for cutting. After one or several sections have been sliced from the tissue specimen by the microtome knife, the pan may again be secured onto the identification mold in a snap-fit relation so as to cover the exposed tissue surface and present the same from becoming soiled or damaged during the usual extended storage for possible later reference to the same patient. At any later time, the tissue specimen may be removed from storage and made available for further sectioning by removing the same from the storage drawer and inserting it into the microtome as described above. The absence of flanges on the identification mold as found in the prior art plus the compact size of the invention facilitates storage of more units in the same space.
Therefore, the object of the invention is generally to improve on the device of U.S. Pat. No. 3,456,300 while retaining its many advantages but principally to substantially reduce the amount of space required when processing with such a device as a receptacle.
Other objects and advantages of this invention will become apparent when the following detailed description is read in conjunction with the appended drawings and claims. A preferred embodiment of this invention will now be described with reference to the accompanying drawings, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the compact-telescoping processing and embedding unit of this invention showing the various elements in an interconnected relationship as they are assembled to form the processing unit.
FIG. 2 is a perspective view of the perforated top section.
FIG. 3 is a perspective view of the pan section.
FIG. 4 is a perspective view of the identification mold section.
FIG. 5 is a perspective view of the various elements and the identification mold as they are assembled to form the processing unit.
FIG. 6 is a perspective view of the pan section and the identification mold as they are assembled to form the embedding unit.
FIG. 7 is a section view taken along lines 7--7 of FIG. 1 and showing the invention structure as it appears in service as a receptacle for receiving and processing a tissue specimen through the various processing liquids.
FIG. 8 is a section view taken along lines 8--8 of FIG. 6 and showing the invention structure as it appears in service as the embedding unit prepared to receive the melted paraffin for embedding the tissue specimen in a paraffin block.
FIG. 9 is a section view of the embedding unit with the tissue specimen embedded in the solidified paraffin.
FIG. 10 is a section view showing the identification mold portion of the finished unit clamped between opposed jaws of a microtome with the lip of the pan ledge abutting against the jaws and thereby acting as a means of aligning the embedded specimen to be sliced by the microtome cutting blade.
FIG. 11 is a section view like FIG. 10 with the pan section removed so as to present the tissue specimen to the knife of the microtome.
FIG. 12 is an enlarged pictorial view of the tissue specimen at it appears embedded in the exposed paraffin block and mounted for cutting by the microtome.
FIG. 13 is a section view comparable to FIG. 7 of the prior art device of the U.S. Pat. No. 3,456,300 in use as a receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The first element of the compact-telescoping processing and embedding structure when assembled as the compact processing unit 10 is a perforated top 11 which includes a rectangular central plate 16 and two perpendicularly downward extending sidewalls 12 and 13 which are integrally connected to plate 16 along the end edges thereof. Sliding tongue members 14 and 15 are inward turning, perpendicular continuations of sidewalls 12 and 13 but are of a shorter length than sidewalls 12 and 13. Perforated top 11 serves as a means of admitting the various processing fluids, including hot liquid paraffin, into the compact processing unit 10 and the perforations are provided by a plurality of openings 17 through which the various liquids may pass. Perforated top 11 is preferably molded from a thin resilient plastic such as a polyformaldehyde resin or metal which is inert to and will not float in the various processing liquids and which will withstand the usual processing temperatures. Top 11 may be disposable if made of plastic and reusable if made of metal. Further, top 11 is also provided with a plurality of knobs 18 which extend outwardly from the top surface of plate 16 and which provide means for spacing several of the structures 10 from each other when the same are stacked side by side during the fixation process and which allows the fixation fluids to enter and leave the openings 17.
The second element of the compact structure 10 is the pan section 20, which like top 11, may also be molded of polyformaldehyde resin material or of metal and is comprised of a thin, heat conducting bottom wall 27, the outside surface of which may be etched to receive indicia, and sidewalls 23, 24, 25 and 26 which intersect bottom wall 27 at an approximate off-vertical angle of 03° from top to bottom to form an open topped rectangular box. The 03° inward angle of sidewalls 23, 24, 25 and 26 corresponds to a similar slope of the outer walls of pan section 20 and enables pan section 20 to telescope snugly within sidewalls 34, 35, 36 and 37 of identification mold 30. The upper outer edges of sidewalls 23, 24, 25 and 26 of pan section 20 are provided with a continuous generally horizontal exterior ledge or flange 21, which forms an angle of approximately 93° with the sidewalls 23, 24, 25 and 26. A shallow, continuous lip 22 extends perpendicularly upward from the outside edges of the flange or pan ledge 21 such that when pan section 20 is telescoped within identification mold 30 for processing, pan ledge 21 overlaps and rests on the top edges of the identification mold sidewalls 34, 35, 36 and 37. Later, when the relative positions of pan section 20 and identification mold 30 are reversed in order to form the embedding unit shown in FIG. 6, pan ledge 21 acts as a base on which the bottom edges of identification mold sidewalls 34, 35, 36 and 37 may rest. At the same time, lip 22 both prevents identification mold 30 from shifting position on pan ledge 21 and effects a snug, snap-fit joint between pan section 20 and identification mold 30 which prevents the leaking of paraffin during embedding. Whether pan section 20 is molded of polyformaldehyde resin or metal, pan bottom 27 should have the character of thinness in the order of from 0.020 to 0.050 inch thick to rapidly conduct heat and rapidly cool the specimen as required just prior to embedding.
The third and previously mentioned element of the compact processing structure 10 is an open mold 30, referred to as identification mold 30, which, like top 11 and pan section 20, is preferably also molded of polyformaldehyde resin material and is comprised essentially of four integrally connected sidewalls 34, 35, 36 and 37 whose exterior surfaces intersect at right angles so as to form an open-ended box which is rectangular in cross section, both longitudinally and laterally. The exterior surfaces of sidewalls 35 and 37 are flat and one or both are etched to receive appropriate indicia. The exterior surfaces of sidewalls 34 and 36 are also flat but are interrupted by longitudinal grooves 31 and 32 which extend respectively from the exterior intersection of sidewall 34 and sidewall 35 and from the exterior intersection of sidewall 36 and sidewall 35 and terminate at equidistant points on both sidewalls 34 and 36, said points lying just short of the exterior intersections of sidewalls 34 and 37 and sidewalls 36 and 37. The lower edges of sidewalls 34, 35, 36, and 37 are provided with a short, continuous interior mold ledge 33, which extends inward from the lower edges of said sidewalls 34, 35, 36 and 37. The interior surfaces of sidewalls 34, 35, 36 and 37 are smooth and intersect identification mold ledge 33 at an approximate angle of 93°. This inward angle relation produces a greater thickness for the lower portions of sidewalls 34 and 36 thereby enabling sidewalls 34 and 36 to accommodate grooves 31 and 32. Identification mold ledge 33 serves as a resting shelf for the outer edges of pan bottom 27 when pan section 20 is telescoped within identification mold 30. A further and more important function of identification mold ledge 33 is to act as a gripping or trapping member for securing paraffin block 46 to identification mold 30 as best shown in FIGS. 9, 10 and 11 which eliminates the need for projections or like interior configurations to secure the molded block to the interior wall surfaces of identification mold 30, presents the least opposition to the flow of processing fluids and makes it practical to position the tissue specimen 45 in pan 20 when identification mold 30 is seated atop pan section 20 as shown in FIG. 6. While similar advantages are to be found in the device of U.S. Pat. No. 3,456,300, they have not been previously obtained in a shallow depth, multi-purpose unit as with the present invention.
In operation, pan section 20 is first telescoped within identification mold 30.
It should be noted that the manner in which the mold and pan members are shaped with the described interior angled wall and block securing ledge, the pan section can be inserted into the mold member only through the open end of the mold member opposite ledge 33 and the pan section is blocked from entry through the opposite end of the mold member. Further, the described tongue and groove securing arrangements for securing the top member operate when the pan section is properly nested, thus proper assembly of the receptacle is always assured.
The specimen accession number is next written on one or both of the etched exterior surfaces of identification mold walls 35 and 37. Note here that the use of the identification mold as part of the processing receptacle during processing insures that the mold and specimen always stay together and that the specimen is always identifiable by indicia on the mold. This is particularly significant since the top is normally discarded after processing and the pan section becomes separated from the specimen during slicing. Tissue specimen 45 is then placed on pan bottom 27 after which tongue members 14 and 15 of top 11 are aligned with and inserted into the open ends of grooves 31 and 32 of identification mold 30. Top section 11 is then slid into place as indicated in FIG. 5. Completion of the sliding action results in the creation of the compact, shallow depth perforate processing unit 10 of FIG. 1. It is contemplated that a plurality of processing units 10 will be stacked in a tissue processing basket with knobs 18 spacing adjacent compact processing units 10.
What should be particularly appreciated at this point in the description is that the improved telescoping pan-mold and top securing arrangement of the present invention provides a processing unit 10 of relatively shallow depth as compared to the processing device of U.S. Pat. No. 3,456,300. To illustrate, FIG. 13 shows the patent device and it will be noted that the receptacle depth D 1 is obtained by effectively stacking the covered mold on the pan of the patent device. In comparison, the receptacle depth D 2 of the invention is effectively only the depth of the pan. Thus, in the preferred embodiment previously described, the receptacle depth of the invention device for purpose of processing is substantially half that of the patent device. Therefore, in a given space with the invention receptacle, twice as many receptacles and twice as many specimens may be processed. However, as with the patent device, the identifying mold always stays with the specimen, thus the critical identification, once properly applied to the mold cannot be lost or separated from the specimen except by very gross error in procedure.
The processing basket, once filled with the processing units 10, is then placed within an automatic tissue processor where the tissue specimens 45 undergo exposure to various processing liquids which enter and exit through perforations 17 in top 11. The final liquid to which tissue specimen 45 is exposed is hot paraffin whereupon quantities of the melted paraffin are transferred by osmosis into the tissue cells. The basket is then removed from the processor and the units 10 are removed and placed on a heated surface. Top section 11 is removed by a reverse sliding action wherein sliding tongue members 14 and 15 are slid backwards out of grooves 31 and 32 of identification mold 30.
After removal of top 11, the heretofore compact processing unit 10 is now ready to be transformed into the embedding unit 40 of FIG. 6. This is accomplished by removing pan 20 from its telescoped position within identification mold 30 and then placing identification mold 30 on top of pan 20 where it rests on pan ledge 21 and is snap-fit secured in this position by lip 22. The structure of the now assembled embedding unit 40 is shown in FIG. 6. Embedding unit 40 is next partially filled with liquid paraffin and transferred to a cold surface whereupon the paraffin begins to solidify. As the paraffin solidifies, tissue specimen 45 is repositioned so that the precise plane of cutting may be achieved. After tissue specimen 45 has been properly repositioned on bottom 27 of pan 20, embedding unit 40 is placed under an orifice which then supplies additional liquid paraffin to embedding unit 40, such liquid paraffin filling embedding unit 40 to a level substantially level to the open end of identification mold 30. The paraffin is then cooled to form paraffin block 46 which contracts and assumes the shape shown in FIG. 9, completely embedding specimen 45. It can be seen from FIG. 9 that paraffin block 46 extends above identification mold ledge 33 so that upon removal of pan section 20, paraffin block 46 is securely trapped within identification mold 30.
Embedding unit 40, which now includes paraffin block 46, is ready to be positioned between opposing microtome jaws 47 and 48. This is accomplished by inserting sidewalls 35 and 37 of identification mold 30 between microtome jaws 47 and 48, as shown in FIG. 10, until selected edges of pan lip 22 abut against the ends of jaws 47 and 48. It is this abutment of lip 22 which acts to correctly align embedding unit 40 so that when pan section 20 is removed from block 46, as shown in FIG. 11, block 46 will be substantially parallel to microtome blade 49 as shown in FIG. 12. This arrangement, as previously mentioned, eliminates the need for aligning flanges on identification mold 30 but nevertheless results in accurate alignment. When pan 20 has been removed from block 46, as illustrated in FIGS. 11 and 12, tissue slices 50 are cut from block 46 and after the required number of slices 50 have been taken from block 46, pan 20 may be repositioned onto identification mold 30 so as to protect tissue specimen 45 and to provide abutting surfaces if it is ever desirable to replace and realign paraffin block 46 in microtome jaws 47 and 48 for further severance of the same. | A three-part histologic tissue receptacle and embedding structure comprises an identification, open-ended, mold section, a pan section, and a perforated top section which can be slid over the mold and pan sections and retain all three sections in a closed relation. The mold, pan and top sections of the structure may be arranged for service, with the pan telescoped in the mold section, as a perforate, integral, shallow depth, receptacle for holding and transporting the tissue specimens through various liquids during processing, as a mold for embedding the specimen, as a holder for holding the embedded specimen in a microtome during slicing and after slicing, as a housing for holding and protecting the remaining unsliced embedded specimen during extended storage. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation, under 35 U.S.C. §120, of copending international application No. PCT/EP2006/012310, filed Dec. 20, 2006, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of European patent application No. EP 05 028 540.2, filed Dec. 22, 2005; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to cathodes for aluminum electrolysis cells formed of cathode blocks and current collector bars attached to the blocks whereas the cathode slots receiving the collector bar are lined with expanded graphite. As a consequence the contact resistance between the cathode block and a cast iron sealant is reduced giving a better current flow through the interface. Hence, partial slot lining in the center of the slot can be used to create a more uniform current distribution. This provides longer useful lifetime of such cathodes by reduced cathode wear and thus increased cell productivity. In addition, expanded graphite also acts as a barrier against deposition of chemical compounds at the interface between the cast iron sealant and the cathode block. It also buffers thermomechanical stresses, depending on the specific characteristics of the selected expanded graphite quality.
Aluminum is conventionally produced by the Hall-Heroult process, by the electrolysis of alumina dissolved in cryolite-based molten electrolytes at temperatures up to around 970° C. A Hall-Heroult reduction cell typically has a steel shell provided with an insulating lining of refractory material, which in turn has a lining of carbon contacting the molten constituents. Steel-made collector bars connected to the negative pole of a direct current source are embedded in the carbon cathode substrate forming the cell bottom floor. In the conventional cell configuration, steel cathode collector bars extend from the external bus bars through each side of the electrolytic cell into the carbon cathode blocks.
Each cathode block has at its lower surface one or two slots or grooves extending between opposed lateral ends of the block to receive the steel collector bars. The slots are machined typically in a rectangular shape. In close proximity to the electrolysis cell, the collector bars are positioned in the slots and are attached to the cathode blocks most commonly with cast iron (called “rodding”) to facilitate electrical contact between the carbon cathode blocks and the steel. The thus prepared carbon or graphite made cathode blocks are assembled in the bottom of the cell by using heavy equipment such as cranes and finally joined with a ramming mixture of anthracite, coke, and coal tar to form the cell bottom floor. A cathode block slot may house one single collector bar or two collector bars facing each other at the cathode block center coinciding with the cell center. In the latter case, the gap between the collector bars is filled by a crushable material or by a piece of carbon or by tamped seam mix or preferably by a mixture of such materials.
Hall-Heroult aluminum reduction cells are operated at low voltages (e.g. 4-5 V) and high electrical currents (e.g. 100,000-350,000 A). The high electrical current enters the reduction cell from the top through the anode structure and then passes through the cryolite bath, through a molten aluminum metal pad, enters the carbon cathode block, and then is carried out of the cell by the collector bars.
The flow of electrical current through the aluminum pad and the cathode follows the path of least resistance. The electrical resistance in a conventional cathode collector bar is proportional to the length of the current path from the point the electric current enters the cathode collector bar to the nearest external bus. The lower resistance of the current path starting at points on the cathode collector bar closer to the external bus causes the flow of current within the molten aluminum pad and carbon cathode blocks to be skewed in that direction. The horizontal components of the flow of electric current interact with the vertical component of the magnetic field in the cell, adversely affecting efficient cell operation.
The high temperature and aggressive chemical nature of the electrolyte combine to create a harsh operating environment. Hence, existing Hall-Heroult cell cathode collector bar technology is limited to rolled or cast mild steel sections. In comparison, potential metallic alternatives such as copper or silver have high electrical conductivity but low melting points and high cost.
Until some years ago, the high melting point and low cost of steel offset its relatively poor electrical conductivity. The electrical conductivity of steel is so poor relative to the aluminum metal pad that the outer third of the collector bar, nearest the side of the pot, carries the majority of the load, thereby creating a very uneven cathode current distribution within each cathode block. Because of the chemical properties, physical properties, and, in particular, the electrical properties of conventional cathode blocks based on anthracite, the poor electrical conductivity of steel had not presented a severe process limitation until recently. In view of the relatively poor conductivity of the steel bars, the same rationale is applicable with respect to the relatively high contact resistance between cathode and cast iron that has so far not played a predominant role in cell efficiency improvement efforts. However, with the general trend towards higher energy costs, this effect becomes a non-negligible factor for smelting efficiency.
Ever since, aluminum electrolysis cells have increased in size as the operating amperage has increased in pursuit of economies of scale. As the operating amperage has been increased, graphite cathode blocks based on coke and pitch instead of anthracite have become common and further the percentage of graphite in cathodes has increased to take advantage of improved electrical properties and maximize production rates. In many cases, this has resulted in a move to partially or fully graphitized cathode blocks. Graphitization of carbon blocks occurs in a wide temperature range starting at around 2000° C. stretching up to 3000° C. or even beyond. The terms “partially graphitized” or “fully graphitized” cathode relate to the degree of order within the domains of the carbon crystal structure. However, no distinct borderline can be drawn between those states. Principally, the degree of crystallization or graphitization, respectively, increases with maximum temperature as well as treatment time at the heating process of the carbon blocks. For the description of our invention, we summarize those terms using the terms “graphite” or “graphite cathode” for any cathode blocks at temperatures above around 2000° C. In turn, the terms “carbon” or “carbon cathode” are used for cathode blocks that have been heated to temperatures below 2000° C.
Triggered by the utilization of carbon and graphite cathodes providing higher electrical conductivities, increasing attention had to be paid to some technical effects that were so far not in focus: wear of cathode blocks; uneven current distribution; and energy loss at the interface between cathode block and cast iron.
All three effects are somewhat interlinked and any technical remedy should ideally address more than one single item of this triade.
The wear of the cathode blocks is mainly driven by mechanical erosion by metal pad turbulence, electrochemical carbon-consuming reactions facilitated by the high electrical currents, penetration of electrolyte and liquid aluminum, as well as intercalation of sodium, which causes swelling and deformation of the cathode blocks and ramming mixture. Due to resulting cracks in the cathode blocks, bath components migrate towards the steel cathode conductor bars and form deposits on the cast iron sealant surface leading to deterioration of the electrical contact and non-uniformity in current distribution. If liquid aluminum reaches the iron surface, corrosion via alloying immediately occurs and an excessive iron content in the aluminum metal is produced, forcing a premature shut-down of the entire cell.
The carbon cathode material itself provides a relatively hard surface and had a sufficient useful life of five to ten years. However, as the contact voltage drop at the interface between the cast iron sealant and the cathode blocks becomes the dominant detrimental effect to the overall cathode voltage drop (CVD) with increasing cell lifetime, the cells mostly need to be relined for economical reasons before the carbon lining is actually worn out.
Most likely the increasing contact voltage drop at the interface between the cast iron sealant and the cathode blocks can be attributed to a combination of two subordinated effects. Aluminum diffused through the cathode block forms insulating layers, e.g. of β-alumina, at the interface. Secondly, steel as well as carbon are known to creep when exposed to stress over longer periods. Both subordinated effects can be attributed to cathode block wear as well as uneven current distribution and vice versa does the resulting contact voltage drop detrimentally influence those other two effects.
Cathode block erosion does not occur evenly across the block length. Especially in the application of graphite cathode blocks, the dominant failure mode is due to highly localized erosion of the cathode block surface near its lateral ends, shaping the surface into a W-profile and eventually exposing the collector bar to the aluminum metal. In a number of cell configurations, higher peak erosion rates have been observed for these higher graphite content blocks than for conventional carbon cathode blocks. Erosion in graphite cathodes may even progress at a rate of up to 60 mm per annum. Operating performance is therefore traded for operating life.
There is a link between the rapid wear rate, the location of the area of maximum wear, and the non-uniformity of the cathode current distribution. Graphite cathodes are more electrically conductive and as a result have a much more non-uniform cathode current distribution pattern and hence suffer from higher wear.
In U.S. Pat. No. 2,786,024 (Wleügel) it is proposed to overcome non-uniform cathode current distribution by utilizing collector bars that are bent downward from the cell center so that the thickness of the cathode block between the collector bar and the molten metal pad increases from the cell center towards the lateral edges. Manufacturing and transportation issues related to such curved components prevented this approach to become used in practice.
German patent No. DE 2 624 171 B2 (Tschopp), corresponding to U.S. Pat. No. 4,110,179, describes an aluminum electrolysis cell with uniform electric current density across the entire cell width. This is achieved by gradually decreasing the thickness of the cast iron layer between the carbon cathode blocks and the embedded collector bars towards the edge of the cell. In a further embodiment of that invention, the cast iron layer is segmented by non-conductive gaps with increasing size towards the cell edge. In practice however, it appeared too cumbersome and costly to incorporate such modified cast iron layers.
In U.S. Pat. No. 6,387,237 (Homley et al.) an aluminum electrolysis cell with uniform electric current density is claimed containing collector bars with copper inserts located in the area next to the cell center thus providing higher electrical conductivity in the cell center region. Again, this method did not find application in aluminum electrolysis cells due to added technical and operational complexities and costs in implementing the described solution.
In addition, either prior art approach considered merely the uniform current distribution within the horizontal plane along the length axis of the carbon cathode block and collector bar, respectively. However, the other dimension, namely the horizontal plane across the cathode block width also plays a significant role when considering the electrical current passing through the cell from the anode down to the collector bar.
Accordingly, in order to fully realize the operating benefits of carbon and graphite cathode blocks without any trade-offs with regards to existing operational procedures and related costs there is a need for decreasing cathode wear rates and increasing cell life by providing a more uniform cathode current distribution and at the same time providing measures for an improved and sustained electrical contact at the interface between the cast iron sealant and the cathode block.
Further, there is a need to provide a more uniform cathode current distribution not just along the block length but also across its width.
In addition, the step of casting iron into the slots in order to fix the collector bars (called “rodding”) is cumbersome and requires heavy equipment and manual labor. To further simplify cathode assembly procedures, there is a need to completely avoid casting iron in order to fix the collector bars to the cathodes.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide cathodes for an aluminum electrolysis cell with an expanded graphite lining, that overcomes the above-mentioned disadvantages of the prior art devices and methods of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, a cathode for an aluminum electrolysis cell. The cathode contains a cathode block, being either a carbon cathode block or a graphite cathode block, and has a collector bar slot formed therein. A steel-made current collector bar is disposed in the collector bar slot; and an expanded graphite lining lines the collector bar slot.
It is therefore an object of the present invention, to provide cathode blocks with slots to receive the collector bars, characterized by the slots being lined fully or partially with expanded graphite. Expanded graphite (EG) provides a good electrical and thermal conductivity especially with its plane layer. It also provides some softness and a good resilience making it a common material for gasket applications. Those characteristics render it an ideal material to improve the contact resistance between the graphite block and the cast iron sealant. The resilience also significantly slows down the gradual increase of contact voltage drop at the interface between the cast iron and the cathode blocks during electrolysis as it can fill out the gaps formed due to creep of steel as well as carbon. Gradual increase of contact voltage drop at the interface between the cast iron and the cathode blocks is further reduced especially by the EG lining at the bottom face of the cathode slot as it acts as barrier to e.g. aluminum diffused through the cathode block, thus preventing formation of insulating layers, e.g. of β-alumina, at the interface.
Further, the resilience of EG eases mechanical stress due to different coefficients of thermal expansion occurring between the steel collector bar, the cast iron and the cathode block. Thermal expansion of the different materials occurs mainly during pre-operational heating-up of the electrolysis cell and also during rodding and frequently results in cracks in the cathode block that further reduce their lifetime.
It is another object of the invention to provide cathode blocks having the slot completely lined with EG. In that case, the electrical contact to the cast iron is improved throughout the entire slot area.
It is another object of the invention to provide cathode blocks having the slot partially lined with EG.
In a preferred embodiment, the slot is lined with EG only at its both side faces. This embodiment facilitates a more uniform current distribution especially along the cathode block width and eases mechanical stress occurring predominantly at the slot side faces.
It is another object of this invention to provide cathode blocks having the slot lined with EG only at its center area. Through this method, the electrical field lines, i.e. the electrical current, are drawn away from the lateral block edges towards the block center. Further, this embodiment provides a considerable improvement in uniform current distribution not only along the cathode block length but as well as the block width in case that only the slot side faces are lined with EG.
It is another object of the invention to provide cathode blocks having the slot lined with EG of different thickness and/or density. As the operational temperatures are higher at the cell center, the management of thermal expansion and creep of the various materials is more challenging at the cathode (i.e. cell) center. Hence, an EG lining with higher thickness and/or lower density should be preferably placed at the cathode center area to gap a longer resilience “pathway”.
The same principle can be applied by lining the slot bottom face with a thinner and/or denser lining than both side faces where mechanical stresses prevail.
It is another object of the invention to provide a method of manufacturing cathodes for aluminum electrolysis cells by manufacturing a carbon or graphite cathode block, lining the slot with EG and finally attaching a steel collector bar to such lined block by cast iron.
It is another object of this invention to provide cathodes for aluminum electrolysis cells containing a carbon or graphite cathode block having an EG lining in their slot and a steel collector bar directly fixed to such cathode block.
In a preferred embodiment, such carbon or graphite cathode blocks are provided with decreased slot dimensions.
It is another object of the invention to provide a method of manufacturing cathodes for aluminum electrolysis cells by manufacturing a carbon or graphite cathode block, lining the slot entirely with EG and finally directly attaching a steel collector bar to such lined block without cast iron.
In a preferred embodiment, the EG lining in form of a foil is first fixed with glue to the collector bar covering the surfaces opposing the slot surfaces, the thus prepared collector bar is finally inserted into the slot.
It is another object of the invention to provide a method of manufacturing cathode blocks having the slot lined with EG, whereas the EG lining in form of a foil is fixed to the cathode by glue.
In a preferred embodiment, the EG lining in form of a foil is fixed to the collector bar and/or the cathode by applying glue in selected areas only.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in cathodes for an aluminum electrolysis cell with an expanded graphite lining, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagrammatic, cross-sectional view of a prior art electrolytic cell for aluminum production showing the cathode current distribution;
FIG. 2 is a diagrammatic, side view of the prior art electrolytic cell for aluminum production showing the cathode current distribution;
FIG. 3 is a diagrammatic, side view of a cathode according to the invention;
FIG. 4 is a diagrammatic, cross-sectional view of the electrolytic cell for aluminum production with a cathode according to the invention showing the cathode current distribution;
FIG. 5 is a diagrammatic, side view of a cathode according to the invention, depicting a preferred embodiment of the invention;
FIG. 6 is a diagrammatic, side view of an electrolytic cell for aluminum production with a cathode according to the invention showing the cathode current distribution.
FIG. 7 is a diagrammatic, top perspective view of a cathode according to the invention, depicting a preferred embodiment of this invention;
FIG. 8 is a diagrammatic, side view of the cathode according to the invention, depicting a preferred embodiment of this invention;
FIG. 9 schematically depicts the laboratory test setup for testing the change of through-plane resistance under load; and
FIG. 10 is a graph showing results obtained from testing the change of through-plane resistance under load using expanded graphite foil.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a cross-sectional view of an electrolytic cell for aluminum production, having a prior art cathode 1 . A collector bar 2 has a rectangular transverse cross-section and is fabricated from mild steel. It is embedded in a collector bar slot 3 of a cathode block 4 and connected to it by a cast iron layer 5 . The cathode block 4 is made of carbon or graphite by methods well known to those skilled in the art.
Not shown are the cell steel shell and the steel-made hood defining the cell reaction chamber lined on its bottom and sides with refractory bricks. The cathode block 4 is in direct contact with a molten aluminum metal pad 6 that is covered by a molten electrolyte bath 7 . Electrical current enters the cell through anodes 8 , passes through the electrolytic bath 7 and the molten metal pad 6 , and then enters the cathode block 4 . The current is carried out of the cell via the cast iron 5 by the cathode collector bars 2 extending from bus bars outside the cell wall. The cell is build symmetrically, as indicated by the cell centerline C.
As shown in FIG. 1 , electrical current lines 10 in the prior art electrolytic cell are non-uniformly distributed and concentrated more toward ends of the collector bar at the lateral cathode edge. The lowest current distribution is found in the middle of the cathode 1 . Localized wear patterns observed on the cathode block 4 are deepest in the area of highest electrical current density. This non-uniform current distribution is the major cause for the erosion progressing from the surface of a cathode block 4 until it reaches the collector bar 2 . That erosion pattern typically results in a “W-shape” of the cathode block 4 surface.
In FIG. 2 , a schematic side view of an electrolytic cell fitted with the prior art cathode 1 is depicted. The neighboring cathodes 1 are not shown in FIG. 2 , but generally any further description related to a single cathode is to be applied to the entity of all cathodes of an electrolytic cell. The collector bar 2 is embedded in the collector bar slot 3 of the cathode block 4 and secured to it by the cast iron layer 5 . Electrical current distribution lines 10 in the prior art cathode 1 are non-uniformly distributed and strongly focused towards the top of collector bar 2 .
FIG. 3 shows a side view of an electrolytic cell fitted with the cathode 1 according to the invention. The collector bar 2 is embedded in the collector bar slot 3 of the cathode block 4 and secured to it by the cast iron layer 5 . According to the invention, the collector bar slot 3 is lined with an expanded graphite lining 9 .
The expanded graphite lining 9 according to this invention is preferably used in a form of a foil. The foil is manufactured by compressing expanded natural graphite flakes under high pressure using calander rollers to a foil of a density of 0.2 to 1.9 g/cm 3 and a thickness between 0.05 to 5 mm. Optionally, the foil may be impregnated or coated with various agents in order increase its lifetime and/or adjust its surface structure.
This may be followed by pressing a sandwich of the obtained foil and a reinforcement material to plates having a thickness ranging between 0.5 to 4 mm. Such expanded graphite foil manufacturing processes are well known to those skilled in the art.
The expanded graphite lining 9 is preferably fixed to the collector bar 2 and/or the cathode by applying glue. The glue should preferably be a carbonaqueous compound with few metallic contaminants, such as phenolic resin. Other glues may be used as appropriate. Preferably, the glue is applied in selected areas of the lining only. For example, a punctiform application of the glue is sufficient as the lining should only be fixed for the subsequent casting step. The glue is applied to the side of the trimmed lining that will contact the cathode block 4 . Afterwards, the thus prepared lining is applied preferably by rollers.
After lining the collector bar slot 3 surface with expanded graphite lining 9 , finally a steel collector bar 2 is secured to such lined block by the cast iron layer 5 .
FIG. 4 shows a schematic cross-sectional view of an electrolytic cell for aluminum production with the cathode 1 according to this invention. Below the top face of the collector bar slot 3 , the expanded graphite lining 9 is seen. Due to the cross-sectional viewpoint, both side faces of the collector bar slot 3 , lined with expanded graphite lining 9 are hidden. In comparison to the prior art ( FIG. 1 ), the cell current distribution lines 10 distributed more evenly across the length of the cathode 1 due to the better electrical contact to the cast iron layer 5 facilitated by the expanded graphite lining 9 . However, this embodiment provides also a considerable improvement in uniform current distribution across the cathode block 4 width in comparison with the prior art.
An even more uniform current distribution across the length and/or the width of a cathode 1 can be achieved according the invention if the collector bar slot 3 is lined with expanded graphite lining 9 of different thickness and/or density.
In one embodiment, the collector bar slot 3 is lined with expanded graphite lining 9 that is 10 to 50% thinner and/or 10 to 50% more dense at the cathode center than at its edge.
In another embodiment, the expanded graphite lining 9 at the top face of the collector bar slot 3 is different from the expanded graphite lining 9 at both side faces. Preferably, the collector bar slot 3 is lined with expanded graphite lining 9 that is 10 to 50% thinner and/or 10 to 50% more dense at the top face than at both side faces. This embodiment provides a considerable improvement in uniform current distribution specifically across the cathode block 4 width as well as buffers thermomechanical stress prevailing at the side faces of the collector bar slot 3 .
FIG. 5 shows a side view of an electrolytic cell fitted with the cathode 1 according to the invention. The collector bar 2 is embedded in the collector bar slot 3 of the cathode block 4 and secured to it by the cast iron 5 . According to a preferred embodiment of the invention, only the two side faces of the collector bar slot 3 are lined with an expanded graphite lining 9 .
As depicted in FIG. 6 , this embodiment provides a considerable improvement in uniform current distribution specifically across the cathode block 4 width in comparison with the prior art ( FIG. 2 ). Further, thermomechanical stress prevailing at the side faces of the collector bar slot 3 is buffered.
FIG. 7 shows a schematic top view of the cathode 1 according to the invention, depicting another preferred embodiment of the invention. In FIG. 7 , the cast iron 5 is not shown for simplicity. FIG. 7 rather shows the setup of the cathode 1 before the cast iron 5 is poured into the collector bar slot 3 . In this embodiment, only the two side faces of the collector bar slot 3 are lined with expanded graphite lining 9 only at the center area of the cathode 1 . This embodiment provides for minimal use of expanded graphite lining 9 with most efficient results.
FIG. 8 is a schematic side view of the cathode 1 according to the invention, depicting another preferred embodiment of the invention. In this case, the collector bar 2 is secured to the cathode block 4 merely by an expanded graphite lining 9 without the cast iron 5 . This embodiment makes the laborious casting procedure obsolete and, at the same time, provides the above described advantages of using expanded graphite lining 9 . Preferably, the by the positive locking or friction locking principle. For example, the collector bar slot 3 may have a dovetail shape. Gluing is also appropriate for securing the collector bar 2 to the cathode block 4 .
This embodiment also allows a decrease in the collector bar slot 3 dimensions. FIG. 9 schematically depicts the laboratory test setup for testing the change of through-plane resistance under load. This test setup was used to mimic the effects of using expanded graphite lining 9 for lining the collector bar slot 3 . Various types and thicknesses of expanded graphite foil (for example SIGRAFLEX F02012Z) have been tested using loading/unloading cycles. Specimen size was 25 mm in diameter. The tests were carried out using a universal testing machine (FRANK PRÜFGERÄTE GmbH).
FIG. 10 shows results obtained from testing the change of through-plane resistance under load using expanded graphite foil SIGRAFLEX F02012Z and material of the cathode type WAL65 commercially manufactured by SGL Carbon Group. This result shows the change in through-plane resistance of the prior art system cast iron/WAL65 (marked “without foil”) and the inventive system F02012Z/cast iron/WAL65 (marked “with foil”). A comparison of the two test curves clearly reveals the significant decrease in through-plane resistance especially at lower loadings by the inventive system with expanded graphite. This advantage is also maintained upon load relaxation due to the resilience of the expanded graphite.
Although several drawings show cathode blocks, or parts thereof, having a single collector bar slot, this invention applies to cathode blocks with more than one collector bar slot in the same manner.
The invention is further described by following examples:
EXAMPLE 1
100 parts petrol coke with a grain size from 12 μm to 7 mm were mixed with 25 parts pitch at 150° C. in a blade mixer for 10 minutes. The resulting mass was extruded to blocks of the dimensions 700×500×3400 mm (width×height×length). These so-called green blocks were placed in a ring furnace, covered by metallurgical coke and heated to 900° C. The resulting carbonized blocks were then heated to 2800° C. in a lengthwise graphitization furnace. Afterwards, the raw cathode blocks were trimmed to their final dimensions of 650×450×3270 mm (width×height×length). Two collector bar slots of 135 mm width and 165 mm depth were cut out from each block, followed by lining the entire slot area with an expanded graphite foil type SIGRAFLEX F03811 of 0.38 mm thickness and 1.1 g/cm 3 density. The lining was accomplished by cutting a piece of the expanded graphite foil according to the slot dimensions, applying a phenolic resin glue to one side of this foil in a punctiform manner, and fixing this foil to the slot surface by a roller.
Afterwards, steel collector bars were fitted into the slot. Electrical connection was made in the conventional way by pouring liquid cast iron into the gap between collector bars and foil. The cathode blocks were placed into an aluminum electrolysis cell.
EXAMPLE 2
Cathode blocks trimmed to their final dimensions were manufactured according to example 1. Two parallel collector bar slots of 135 mm width and 165 mm depth each were cut out from each block. Only the vertical sides of the slots were lined with an expanded graphite foil type SIGRAFLEX F05007 of 0.5 mm thickness and 0.7 g/cm 3 density, starting at 80 cm from each lateral end of the block. Afterwards, steel collector bars were fitted into the slots and connection made as in example 1. The cathode blocks were placed into an aluminum electrolysis cell.
EXAMPLE 3
Cathode blocks trimmed to their final dimensions were manufactured according to example 1. Two parallel collector bar slots of 151 mm width and 166 mm depth were cut out of each block. Two collector bars with 150 mm width and 165 mm height were covered with 2 layers of 0.5 mm thick expanded graphite foil type SIGRAFLEX F05007 on three of its surfaces later opposing the slot surfaces. The thus covered bars were inserted into the slots ensuring a moderately tight fit at room temperature. The bars were mechanically fastened to prevent them from sliding out while handled. Afterwards, the cathode blocks were placed into an aluminum electrolysis cell.
Having thus described the presently preferred embodiments of our invention, it is to be understood that the invention may be otherwise embodied without departing from the spirit and scope of the following claims. | Cathodes for aluminum electrolysis cells are formed of cathode blocks and current collector bars attached to those blocks. The cathode slots receiving the collector bar are lined with expanded graphite lining thus providing longer useful lifetime of such cathodes and increased cell productivity. The expanded graphite provides a good electrical and thermal conductivity especially with its plane layer. | 2 |
This application is a 371 of PCT/CA03/00656, filed May 9, 2003 (designating the U.S.; and which published in English in WO 03/095369 on Nov. 20, 2003), which claims the benefit of German Patent Application No. 102 21 037.3, May 10, 2002, incorporated herein by reference.
FIELD OF THE INVENTION
In one of its aspects, the present invention relates to a double-walled chamber, particularly such a chamber suitable use in the ultraviolet (UV) treatment or disinfection of liquids, preferably drinking water and/or wastewater.
DESCRIPTION OF THE PRIOR ART
UV radiation chambers are usually round boiler-like vessels through which the medium to be treated flows axially. Typically, a conventional UV radiation chamber is provided with inlet and outlet connections laterally at the end, partly also with axially directed outlets. It is conventional that the inlet and outlet connections, like other pressure vessels, are manufactured from round pipes, typically standardized special steel pipes.
The pipe connections and/or the round boiler-like chamber or vessel tolerate high internal pressures at a use of minimal material. The circular shape of the boiler-like chamber or vessel is the optimal solution. In such a round vessel there are disposed the radiation devices which emit radiation, preferably for disinfection of the fluid medium being treated. These are configurations (arrays) of UV radiation devices which are inserted into a UV-permeable thin-walled quartz tubes for protection against low temperature and humidity. With a few exceptions, the UV radiation devices are disposed longitudinally in the tube-like UV radiation chambers, meaning that they are arranged such that their longitudinal axis is substantially parallel to the direction of fluid flow through the chamber or vessel.
It is normally the goal of the designer to produce the most homogeneous UV radiation field with approximately the same intensity of radiation at each place within the chamber. Thus, the goal is to treat the liquid molecules or “particles” such that they are disinfected in their entirety and each molecule or “particle” individually is subjected to the same radiation “H” (mJ/cm 2 ; J/m 2 ).
In a hydraulic system, the cross-flow of the radiation chamber should occur, if possible, in the form of a piston flow (plug flow) along the chamber axis with an overlap by many co-running inner transversal flow components, i.e., radial side flow movements. Only in this way will the individual liquid molecules or “particles” move again to the direct vicinity of the quartz cladding tubes in which the UV radiators are situated and where there is a high radiation intensity and the destruction of germs or microorganisms occurs nearly directly. Such a flow behavior enhances the disinfection performance of the UV treatment device.
The classical ideal and laminar flow pattern is therefore not desirable. It has been noticed, however, that such a flow pattern can be achieved more easily from a technical viewpoint than the truly “ideal” flow for an effective UV de-germination, which depends predominantly on the design of the chamber and the inlet and outlet conditions of the same. The occurrence of dead zones by the lateral entrance of the medium into the cylindrical radiation chamber which are caused by too fast and uncontrollable deflection of the incoming liquid stream and a lack of inner radial movement components often prevent the utilization of the theoretically available radiation space (radiation duration) in the cylindrical radiation chambers.
An additional factor is that the UV radiation sources or lamps disposed along the chamber cannot be conveniently arranged in a circular pattern such that one can refer to a homogeneous radiation field over the cross section and thus in the entire chamber volume. Typically, homogeneous radiation fields are only achieved with even rectangular grid arrays of radiation sources or lamps which demand a rectangular, and preferably square flow cross section. Unfortunately, such an arrangement becomes problematic, however, when a considerable pressure prevails in the interior of the chambers, which is nearly always the case in the treatment of drinking water.
In summary, it can be said that the usual cylindrical UV radiation chambers with the lateral inlets and axially parallel UV radiator arrangements show three special deficiencies, namely: (i) that dead spaces are produced, (i) that a bunch of radiation sources or lamps cannot be conveniently arranged evenly in a round or circular cross section, and (iii) that the passing main flow is not overlapped by a sufficient number of radial side flows.
Thus, there remains a need in the art for a chamber, vessel or treatment device which obviates or mitigates at least one of the above-mention disadvantages of the prior art, particularly such a chamber, vessel or treatment device for UV irradiation of fluid such was wastewater, drinking water and the like.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel chamber, vessel or treatment device of obviates or mitigates at least one of the above-mentioned disadvantages of the prior art.
According in one of its aspects, the present invention provides a double-walled chamber for the UV disinfection of liquids comprising: (i) an inlet connection; (ii) an outlet connection; (iii) an outer pipe which encloses an inner pipe in which at least on UV radiation source is disposed and at whose ends there is a sealing cover in which there can also be an outlet and/or inlet opening, characterized in that the entrance of the liquid into the inner pipe with the radiation devices occurs through the intermediate space between the outer and inner pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:
FIG. 1 a illustrates a first preferred embodiment of the present invention;
FIG. 1 b is a sectional view along line AB in FIG. 1 a;
FIGS. 2 , 2 a , 2 b , 2 c and 2 d illustrate a second preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Thus, a preferred embodiment of the present invention is illustrated in FIGS. 1 a and 1 b , in which, for clarity, the UV radiation devices, i.e. the UV radiation sources or lamps with the cladding tubes and the radiation source or lamp hatches, are not shown. Instead, there is illustrated only the double chamber with the guidance of the passing medium.
With reference to FIGS. 1 a and 1 b , reference numeral 1 relates to the thin-walled inner pipe of any random cross-section, e.g., a square cross section, in which the UV radiation source or lamp configuration is disposed. Reference numeral 2 relates an outer pressure-tight round pipe with an inlet nozzle 4 and an outlet nozzle 5 . Reference numeral 3 relates to the intermediate space between the two pipes 1 and 2 .
The inner pipe 1 is tightly connected with the round floor 6 , e.g., by welding on the face surface at the outlet end of the chamber and centering by means of the adapted separating wall 7 at the end side. The inner pipe 1 , which is the actual radiation chamber with the radiation devices (again not shown for clarity), is provided at its inlet end with a circular ring of round inlet openings 8 and the baffle plate 9 at the outlet end.
According to this preferred embodiment of the invention, the liquid medium reaches from the inlet nozzle 4 at first into the intermediate space 3 and from there by the circularly arranged inlet openings the inner pipe 1 , which is the actual radiation chamber. Since virtually the same pressure prevails in the intermediate space 3 and in the inner pipe 1 , the inner pipe 1 can be produced irrespective of its shape of thin-walled sheet metal, which facilitates production considerably.
The outer pipe 2 is a round pipe which can be pressurized from the inside and can be produced from a relatively thin-walled material. As is shown particularly in FIG. 1 b , the medium revolves about the inner pipe of square cross section, reaches under virtually the same pressure the conforming inlet openings 8 and passes through the same in separated partial streams with nearly the same injection speed peripherally into the inner pipe 1 . The partial streams meet one another and mix with each other. It is easy to see that in this way turbulence and transverse movement of the fluid is obtained when the partial streams meet each other and that a dead space cannot occur at the inlet.
Notice should further be taken that the liquid flow will yield at the narrow places 9 in the axial direction and that thus the “channel cross section” will expand. It is irrelevant where precisely the inlet nozzle is located on the outer pipe. As is shown with the broken line, it could also be attached at reference numeral 10 from below. This may be of relevance when retrofitting a device, because in this way only a short piece needs to be opened for retrofitting the device when the inlet nozzle and the outlet nozzle are close to one another. One advantage in the arrangement of the inlet nozzle at reference numeral 10 is also that the intermediate space 3 is also continuously flushed.
Thus, some of the advantages of this preferred embodiment of the invention include:
1. A non-round, e.g. square, cross section of the actual UV radiation chamber for an optimal radiator configuration; chamber with a thin-walled housing. 2. Prevention of dead spaces in the inflow region. 3. An outstanding swirling of the medium after the entrance into the UV radiation chamber which is entrained by the main flow.
With reference to FIG. 2 , there is illustrate another embodiment of the present invention.
Thus, FIG. 2 illustrates a double-walled chamber according a preferred embodiment of the present invention an exemplary technical arrangement in a slightly simplified representation. Preferably the material of choice is stainless steel in all parts.
Reference numeral 1 relates to the inner thin-walled pipe with a square cross section, i.e., the actual UV radiation chamber, reference numeral 2 relates to the outer pressure-tight and round pipe and reference numeral 3 to the intermediate space between the two pipes. The wall thickness preferably is about 1.5 mm for the inner pipe and about 3 mm for the outer round pipe. The diameter of the outer pipe is approx. 320 mm. The cross sections and the arrangement of the cladding tubes 19 are shown in broken lines.
Reference numeral 4 relates to the inlet nozzle, which is arranged as a loose rotating flange. Reference numeral 6 relates to the front floor with lead-throughs of the cladding tubes 14 into which the UV radiation sources or lamps 15 are inserted. Reference numeral 16 relates to the press rings with a radiator cable screw connections 17 with O-rings which rest flat on the floor and which seal the cladding tubes 14 in a pressured substantially water-tight manner to the outside.
The discharge of the irradiated water occurs via a central flange connection 28 with the welded stud bolts 30 in the rear chamber floor 29 . The inner pipe 1 , which represents the actual UV radiation chamber, is provided at the inlet end with the inlet openings 8 which are arranged in a ring-like way and is welded on the inner side of the floor all around in a sealed manner to the same. The inlet nozzle 4 is slightly offset to the rear, so that the incoming liquid cannot flow more strongly into the upper inlet openings.
At the outlet end of the double-wall chamber, the inner square pipe is fitted into the separating wall 7 , which is a laser cutting with a plate thickness of 1.5 mm, and welded to the same. The shape of the separating wall 7 is shown by FIG. 2 a . The inner pipe itself consists of two lasered 1.5 mm plate halves which are canted with a defined radius and are to be welded together at an intended narrow bordering 18 .
The configuration 19 shown in FIG. 2 in a sectional view of the nine provided UV low-pressure radiation sources or lamps has been used in the construction in a consistent and aligned manner: starting from floor 6 , in the collecting shield 20 according to FIG. 2 c and in the flow screen 21 according to FIG. 2 d . The cladding tubes 14 are inserted and held in the flow screen 21 and a baffle plate 27 is also lasered into the same. The middle radiator holder 20 has the task of receiving the cladding tubes during the installation and preventing the same from dropping and breaking.
Once the cladding tubes have been inserted into the middle radiator holder 20 , they will always find their fixing device in the flow screen 21 when they are pushed in further. Components 20 and 21 are also laser cuts. They can be produced easily, precisely and cheaply. The important aspect is, which needs to be mentioned specifically, that the mounting of the cladding tubes in the flow screen is made free from play so that they cannot vibrate, which could lead to destruction thereof.
The openings 22 in the flow screen 21 according to FIG. 2 d comprise bending clips 23 which can be bent out to such an extent that the cladding tubes can latch in with the round end 24 practically free from play during the insertion and will thus sit tightly. The welding of the flow screen 21 occurs by turning the welding clips 25 by 90°, whereupon one can weld them at both sides with a weld in the tube and can thus prevent crevice corrosion. In the case of the middle radiator holder 20 , the clips 26 are bent by 90°, a bolt each is welded on to the same, which bolt latches into the provided hole when in position and is welded on consistently from the outside with an HV weld in order to prevent crevice corrosion in this manner. The openings 31 are used for emptying.
With the nine low-pressure radiators with an output of 230 W and a 253.7 nm radiation flux of 80 W one can still disinfect approx. 60 m3/h of cleared and pre-filtered waste water with a transmission of only 0.55% by 1 cm according to EU directives for bathing water.
While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.
All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety | The object of the invention is a double-walled chamber for the UV disinfection of liquids, preferably drinking water and/or waste water. It realizes a rectangular and/or square cross-sectional shape of the UV radiation chamber even at higher pressures, whereby the radiation chamber can moreover be provided with a thin-walled configuration and allows an optimal and close arrangement of UV radiators as compared with a round chamber. By applying the inventive idea, the known dead zones at the entrance are completely eliminated and an entrance turbulence is produced which runs simultaneously with the piston flow in the chamber. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of and is a continuation of U.S. application Ser. No. 13/480,311, filed May 24, 2012, now U.S. Pat. No. 8,448,920, which application was a continuation of application Ser. No. 12/252,992, filed Oct. 16, 2008, which is a continuation of U.S. application Ser. No. 11/327,264, filed Jan. 7, 2006, now abandoned, which is a Continuation-in-Part of U.S. application Ser. No. 11/147,571, filed Jun. 8, 2005, now U.S. Pat. No. 7,823,861, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Numerous small vehicle jacks have been invented to deal with the necessity of raising vehicles smaller than typical automobiles, for purposes of performing repairs and other typical needs. Generally, the jacks have been specific as to what kind of vehicle they were adapted to.
Referring now to U.S. Pat. No. 4,066,243 (Johnson), a jack for the use with automobile bumpers is shown, in which a frame is provided as a support means for a vertical pipe, which has a sleeve, which moves upward and downward around said pipe. A typical floor jack provided the upward lifting force against the sleeve, where the floor jack was attached to the sleeve portion through a ring. This device required a secondary jack, and was limited to the lifting of a vehicle body parts which would comprise a bumper.
Referring now to U.S. Pat. No. 4,123,038 (Meyers), an apparatus is disclosed in which an elaborate load bearing frame is provided, where the apparatus operates using two separate hydraulic jacks. There is no realistic application of this type of device with a small tractor or riding lawn mower.
Portable jacks for small tractors are specifically exampled in U.S. Pat. No. 4,549,721 (Stone), in which a screw-scissors jack was operated to provide lifting force against a framework so as to push the framework upward. It would appear that one of the drawbacks of this invention was that the framework had a rectangular configuration, which would create a problem where a portion of the framework had to be moved under the tractor front wheels. This requirement would present a problem in a situation where the tractor was unable to move under its own power, requiring physical work to move the tractor over the framework assembly. Further, this device would not work properly at a location where the ground on which the tractor was situated was not properly leveled.
Referring now to U.S. Pat. No. 5,358,217 (Dach), the lifting apparatus is disclosed, in which a framework had a narrow front end, and avoided some of the problems inherent in the Stone patent referenced above. This system required a hydraulic cylinder to provide an upward pushing force to lift the item or vehicle. Extended arms had curved metal prongs that were referenced as lifting points. This jack was not intended for use with small tractor wheels, but rather was intended for axle assemblies.
Referring now to U.S. Pat. No. 6,330,997 (McGlaun et al.), a lifting apparatus for small vehicles is shown. The assembly uses pivoting action of its framework to first engage the wheels, and then lift the wheels by pivoting the framework so as to use a lever action to urge the wheels off of the ground.
Referring now to U.S. Pat. No. 6,474,626 (Box), a rack for securing a lawn mower to an elevated position is shown, in which a cage-like framework assembly is provided, and where a flexible webbing is used with a wheel crank to pull the entire lawn mower into an elevated position. This assembly is similar to an automobile rack, with the exception that the lifting framework is rectangular in nature, and supports all four wheels of a push mower on rack.
Further patents have disclosed jacking mechanisms with riding lawn mowers. U.S. Pat. No. 6,516,597 (Samejima et al.) discloses a lawn tractor which allows manipulation of its wheel supports into position so that they can be used to assist in raising up the front end of the lawn tractor.
Referring now to U.S. Pat. No. D 468,512 S (Hernandez), an all-terrain vehicle lift is disclosed, in which a hydraulic cylinder is used, to lift a metal framework that is disposed at the front end of the apparatus. The invention uses a rectangular frame, and a support means for the wheel is limited to a single tire, and not to two wheels, unless they are fairly close together.
SUMMARY OF THE INVENTION
From time to time, small tractors, riding lawnmowers, and other similar vehicles require maintenance requiring that one end of the vehicle be elevated. The use of hydraulic floor jacks do not always provide a single stable support structure, and jack stands are often the wrong size with regard to the elevation requirements for the small vehicles. In some situations, the angle of the vehicle necessary to accomplish the desired elevation of one end of the vehicle, makes the use of small jacks unwieldy, since small hydraulic system jacks only have a single contact point. As the contact point rotates by virtue of the elevation difference between the front and back end of the vehicle, the contact point with the hydraulic jack may become unstable. Further, the amount of elevation necessary will often exceed a hydraulic jack assembly's capability.
A complete apparatus is necessary, where the wheels of the vehicle may be used to elevate the entire end of a vehicle, rather than relying on the frame or other similar contact points available with typical hydraulic jacks for such a vehicle. A means to provide use of a jack with a stationary vehicle is desired, where the supporting structure can be moved into position on a vehicle, without requiring movement of the vehicle onto the jack means itself.
This invention comprises a small portable jack that is intended for use with small tractors, riding lawn mowers, four-wheel sport motorcycles, and other small vehicles. This small vehicle jack support system obviates the need for hydraulic systems, but instead uses a vertical jack bar with a winch system and flexible strap on top of the apparatus to provide the lifting force.
The jack itself has a base that defines a stable platform, also referred to as a support frame, that is intended to slide underneath the front end of the tractor or other vehicle. This jack may also be used on the back end of the tractor or other similar vehicle, but for purposes of discussion, the front end of the vehicle will be used as the example with the lifting method and apparatus for this invention.
The framework that contacts the ground is preferably a rectangular configuration, in which the main frame members comprise parallel side beams, a front cross member, and two rear cross members for additional strength. The rear cross members are typically parallel, and allow a mounting plate to be affixed thereto, using bolts, or any other typical attachment means, such as welding, clamping, or other means commonly known and understood in the art. A vertical frame bar is fixed to the mounting plate, and projects upward.
A lifting frame is provided, in which a center bar is connected at its front end perpendicularly to a cross bar member, where said cross bar member has a length that is equal to or greater than the width of the support frame from side to side. The crossbar and center bar define a T-shaped structure. The crossbar sits upon the support frame, with its ends resting on crossbar rest members, where the crossbar rest members define the widest portion of the support frame.
The center bar has a rigid guide member fixed to each side of the center bar rear end, where the guide members are slightly angled rearward from a 90 degree or perpendicular setting. Each guide member is spaced apart and parallel to each other, defining a gap that is at least as wide as the width of the center bar. The center bar preferably has a width greater than the vertical frame bar. As the guide members are parallel to each other, they allow the vertical frame bar to be positioned between them.
Once the lifting frame is positioned so that the vertical frame bar is situated between the angled guide members, a top roller is placed through its receiving apertures located on the terminating ends of the guide members, so that the vertical frame bar is restrained within the guide member gap area. A bottom roller is also positioned on the opposite side of the vertical frame bar, through the side guide members. The bottom roller, the parallel guide members and top roller function as a sleeve, which fits around the vertical frame bar, allowing the lifting frame to be moved upward and downward, with the gap between the guide members allowing some limited horizontal motion of the lifting frame. This allows for easy adjustment to the position of the lifting frame.
The vertical frame bar supports a winch means on its top end, with a flexible strap providing the pulling force necessary to lift the vehicle. In instances where the apparatus is desired to have height adjustment capability, a separate extension bar is provided, which allows the vertical bar, without any top structures attached, to be inserted into the extension bar.
The extension bar is provided, when greater height is desired, than can be obtained from a standard vertical frame bar. Also, the separate extension bar is provided for the simple need of disassembly and storage when so desired. Since both situations are generally desired, an extension bar is typically used with this apparatus.
The extension bar defines an inner cavity which allows the length of the vertical frame bar to be inserted completely into the extension bar. The extension bar preferably has a width similar to the center bar, with the gap defined between the guide members sufficient to allow said guide members to move freely over the extension bar.
The extension bar supports a platform which in turn supports a geared winch system that operates a flexible strap. The end of the flexible strap defines a hook, which is able to connect to a lifting ring located on the center bar, in proximity to the guide member attachment points with the center bar.
Removable wheel supports are provided, which are defined by a horizontal shaft, with a crossmember spacer which defines prongs on each end of the spacer, with the prongs defining a horizontal extension that is able to impact against the bottom side of a wheel. The prongs are spaced apart to define a gap, with the wheel able to rest between said gap. The wheel support assembly is attached to the crossbar by sliding the shaft into the inlet of said crossbar and securing the shaft and crossbar to each other.
Safety features also include axle guards, which comprise prongs that project upwards from the crossbar, and prevent the axle from slipping off of the crossbar when in use. These prongs are able to be removed when not needed, or able to be positioned as desired so that they are able to provide axle movement restriction as needed. The axle prongs may be fixed to a shaft sleeve, which allows the crossbar to be inserted through it, allowing the prong and shaft sleeve to move along the length of the crossbar, with the axle of the vehicle being lifted able to be secured as to movement against the axle prong.
Once the wheels of the vehicle are secured within the gap between the wheel support spacer prongs, the handle of the winch assembly is turned, causing the flexible strapped to move upward, thus exerting a lifting force against the lift ring. The lifting frame is raised vertically. The weight of the vehicle on the cross bar maintains the orientation of the lifting frame in a fairly horizontal position. The frame is unable to angle downward due to do the top and bottom roller. The strap is withdrawn until the lifting frame has raised the vehicle to the desired level. The winch is locked in position, using the braking systems commonly associated with such winch systems.
One advantage of having a separate extension bar is that the overall height capabilities of the jack can be varied, according to the length of the extension bar. Use of the strap denies the need for any type of hydraulic system, with the winch apparatus providing sufficient force to the strap, especially if the winch apparatus has a geared ratio with regard to the handle movement.
The jack assembly is portable, in the sense that the support frame defines wheel axles that are defined as outwardly protruding axles, that are positioned immediately above the rearmost ends of the side frame members of the support frame, and project outward laterally to the side above the support frame. Wheels are used, which have a radius that very closely equals the distance from the axle to the ground, when the main frame is on ground level. For maximum support and strength, the wheels do not contact the ground surface, when the jack is in use. However, if the front portion of the frame is elevated, rotating the frame about the axles, the frame is angled upward from the rear toward the front. As the frame is elevated at the front, the wheels remain stationary as to location, and as the frame pivots around the axles, not only the front portion of the frame is elevated off of the ground level, but the rearmost portion of the frame is also slightly elevated, allowing the supporting wheels to remain and the single contact points of the apparatus and the ground. The entire apparatus can be manipulated into position so that the center of gravity passes through the wheel axles, making the weight of the apparatus negligible, with regard to movement from one location to another. Once the apparatus is positioned with the center of gravity over the wheel axles, it can be easily rolled from one point to another by a single person.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the improved small vehicle jack, in which the wheel support means and extension bar are shown in an exploded view.
FIG. 2 is a perspective view of the improved small vehicle jack in which the vertical frame bar and comprises the vertical support for the winch system.
FIG. 3 is a perspective view from above a riding lawn mower with the improved small vehicle jack positioned underneath it, with the tires of the riding mower positioned above the wheel support means.
FIG. 4 is a perspective view of the riding mower and vehicle jack, where the jack assembly has been moved to a raised position with the front end of the riding mower shown elevated.
FIG. 5 is an enlarged view of the sleeve assembly, showing the guide members and the top and bottom roller.
FIG. 6 is a side view of the sleeve means, in which the guide member is shown, with the lower and upper rollers shown, and where the safety pin is also shown.
FIG. 7 is a perspective view from above and from the left rear portion of the improved small vehicle jack frame and vertical member, showing the wheel axles without the wheels mounted thereon.
FIG. 8 is a side view showing the resting position of the frame and wheels, and the elevated position of the frame, in relation to the wheels.
FIG. 9 is a cross sectional view of the crossbar and axle hook means.
FIG. 10 is a perspective view of the crossbar and axle hook means, showing the relative position of an axle.
FIG. 11 is a perspective view of the jack showing the frame assembly and support guides in a lowered position.
FIG. 12 is a perspective view of the jack showing the frame assembly, with the crossbar in a raised position, with the support guides and cups supporting the crossbar.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the improved small vehicle jack apparatus 10 is shown. Said apparatus 10 is comprised of a support frame 15 , a lifting frame 60 , a lifting means 42 , and a wheel support means 50 . The support frame 15 is comprised of two generally parallel crossbar rest members 18 and 19 , which are spaced apart by a front member 20 . A further improved configuration is shown also in FIG. 7 , in which the support frame 15 is identical with regard to the front portion, where crossbar rest members 18 and 19 are separated by front member 20 , but where the rear portion of the crossbar rest members 18 and 19 are not angled, but maintain a generally straight configuration. As FIG. 7 depicts, the support frame 15 may also be defined by cross bar rest members 18 and 19 , which are spaced apart by front member 20 , and also spaced apart by back support members 71 and 72 , to form a rectangular configuration. In either configuration, members 18 , 19 and 20 , comprise the portion of the support frame 15 that is actually intended to be moved underneath the vehicle. Back support members 71 and 72 may comprise a single member, and should not be interpreted as being required as two separate members.
In the configuration shown in FIG. 1 , the crossbar rest members 18 and 19 are attached to the front member 20 ends, with angled members 13 fixed to the crossbar rest member 18 and 19 rear ends. The angled side members 13 are angled in relation to each other so that the distance between them becomes closer toward each other along their length from the front toward the rear. The rear ends of the angled side members 13 define end portions 25 that are fixed in relation to each other and which allow a vertical frame bar 14 to be fixed in a vertical position at the rear portion of the apparatus 10 .
As FIG. 7 shows, an axle 21 is provided, which is fixed to the rear end of this apparatus 10 , and which supports wheels 22 located on either side of said support frame 15 . The wheels 22 are fixed in such a manner that the rear portion of the support frame 15 is able to rest on the ground, with the wheels 22 providing ground contact for the rear portion of the support frame 15 if the apparatus 10 is tilted backwards. It should be understood however, that wheels 22 are not required, but are shown in FIGS. 2 and 3 as the preferred manner of construction, since wheels 22 provide for an ease of transportation, in which the support frame forward end is elevated, with the ground contact being borne solely by wheels 22 . This allows ease of movement of the entire apparatus 10 . Referring also to FIG. 8 , the side frame member 18 is shown with the axle 21 and wheel 22 shown. When at rest, the support frame 15 will be in contact with the ground surface. As the front end of the side frame member 18 is elevated at the front, the support frame 15 pivots around the axle 21 , and the entire support frame 15 pivots upward from the ground surface. The entire small vehicle jack 10 will be supported by the wheels 22 , and if the entire jack 10 is pivoted so that the center of gravity is directly over the wheels 22 , the effort to maintain the jack 10 off of the ground is minimized. Movement of the jack 10 is easily accomplished by allowing the wheels 22 to rotate around their axles 21 .
In both the configurations shown in FIGS. 1, 2 and 3 , and that shown in FIGS. 7, 11 and 12 , the gap between the rear end portions 25 of the support frame 15 should be wide enough so as to accommodate the center bar 16 of the lifting frame 60 , and any sleeve means utilized with said lifting frame 60 . As the configuration in FIGS. 7, 11 and 12 show, there is no narrowing of the gap, since the side support members 18 and 19 remain parallel.
The fixed vertical frame bar 14 projects upward from the support frame 15 . In the configuration shown in FIGS. 7, 11 and 12 , the vertical frame bar 14 is fixed to the rear support members 71 and 72 , which comprise the rearmost portion of the small vehicle jack apparatus 10 . As these Figures show, the vertical frame bar 14 is fixed to a support plate 73 , and where the support plate 73 is fixed to the rear support members 71 and 72 , using bolts 74 which are placed through bolt holes 75 in the support plate 73 and also through bolt holes 76 in the rear support members 71 and 72 . It should be understood that the vertical frame bar 14 may be fixed to the support plate 73 in any manner commonly known and understood in the art. Further, the support plate 73 is not required for this invention to operate, but rather the vertical frame bar 14 may be fixed to rear support members 71 and 72 individually or both, through any means commonly known and understood in the art. FIGS. 7, 11 and 12 show an alternative configuration for the rear portion of the jack 10 , with regard to that shown in FIG. 1 . In all other aspects, the operation of the jack 10 is equivalent in all Figures regarding the manner of raising the lifting frame 60 .
As FIGS. 7, 11 and 12 show, the crossbar rest members 18 are generally parallel to one another, and are spaced apart by the front member 20 on the front or forward end, and spaced apart at the back by rear support members 71 and 72 , to form a rectangular configuration. The rectangular configuration is but one of many possible configurations, and this invention should not be considered as being limited to a base having a rectangular configuration only.
FIGS. 11 and 12 further depict the means to support the lifting frame 60 , while it is in a raised position. This means allows additional safety of this invention while in use, in that the means to support the lifting frame provides a stationary support that does not rely on the integrity of any lifting force, but rather provides support underneath the item being elevated.
Said means comprises support guides 82 , which are defined as sleeves that pivot around a pivot bolt 86 , where said bolt is placed though a guide hole 85 , and also through frame hole 85 ′, securing the support guide to the cross bar rest member 18 . When not in use, the support guides 82 may be laid parallel to the crossbar rest member 18 , or taken away by removing the bolt 86 so as to allow the crossbar rest member 18 to be moved independent of the apparatus 10 .
The support guides 82 may comprise members that are adjustable as to length. Where said members are adjustable, the support guides 82 may comprise sleeves, which allow separate solid support guides 89 to be inserted into the sleeve support guides 82 , and are adjustable as to overall length using an adjustment pin 91 , which is inserted through the support guide 82 and one of several adjustment holes placed defined along the length of the solid support guide 89 . The adjustment pin 91 , when placed through the support guides 82 and solid support guides 89 will fix their position relative to each other, and also fix the combined overall length of the combination of both guides 82 and 89 . The top or distal end of the solid support guide 89 defines a cup 83 , which allows it to engage the underside of the item being lifted. Said cup 83 is fixed to the end of the solid support guide 89 . If the adjustable features of this supporting system are not used, but rather the support guides 82 are used without the solid support guides 89 , the cup 83 may be fixed to the top or distal end of the support guides 82 , or said cup 83 may comprise a removal piece, and have a bottom leg extension that is able to be inserted into the support guide 82 in a manner similar to that shown by the solid support guides 83 .
While FIG. 11 shows the support guides 82 in a down or rest position, FIG. 12 depicts the same guides 82 in a perpendicular configuration, with the solid support guides 89 shown extending out of the support guides 83 , and supporting the cross bar 17 of the lifting frame 60 . Since the support guides are secured to the crossbar resting members 18 , and are vertical, they are able to assist in supporting the weight of the vehicle or contrivance being lifted by the apparatus 10 , and provide a useful safety feature so that the lifting force is not wholly dependent solely on the strap 45 during the time that the frame 60 has lifted, and while waiting to be let back down.
FIG. 1 shows a separate extension bar 40 , which fits down over the vertical frame bar 14 . In one of the preferred embodiments, there is no separate extension bar 40 , but the support frame 15 and incorporated vertical frame bar 14 support the winch means 42 . As is shown in FIG. 2 , the vertical frame bar 14 is fixed to the rear ends 25 of the support frame 15 , and projects upward and supports a platform 41 and onto which a winch means 42 is provided. The winch means 42 is comprised of a spool, 62 , a winch support 43 that fixes the position of the spool 62 , and a handle 44 , whose manipulation causes a geared assembly to cause the spool 62 to turn to take up or let out the length of the strap 45 .
A flexible strap 45 is shown in FIG. 1 and in FIG. 2 , where said strap 45 is wound about the spool 62 , with its terminating end defining a hook 46 . The flexible strap 45 is fed off of the spool 62 , and a roller 66 is preferably provided at the edge of the platform 41 which supports the winch means 42 . The flexible strap 45 is not limited to any type of specific material, but could include any type of flexible material that has durability and strength in its resistance to stretching and/or breakage. The term “strap” should be understood to include chains, cables, straps of various material, cords, in any other type of flexible straps may be used, and will all function in virtually the same manner.
As is shown in FIG. 2 , the support frame 15 and incorporated vertical frame bar 14 comprise a general L-shaped configuration, where the total height of the apparatus 10 will always be consistent with the height of the vertical frame bar 14 and winch assembly 42 .
FIG. 1 shows an embodiment of the apparatus 10 in which the vertical frame bar 14 has the same configuration, except that it is much shorter in FIG. 1 than it is in FIG. 2 . In FIG. 1 , an extension bar 40 operates as an extender of the vertical frame bar 14 . The extension bar 40 may have any overall length desired by the operator of this apparatus 10 . In this manner, the interchangeability of various extension bars 40 with a single support frame 15 and vertical frame 14 , allows for a single support frame 15 to provide possibility for an apparatus 10 that has multiple choices of overall height as to the orientation of winch assembly 42 . The winch assembly 42 as described for FIG. 2 operates in the same manner as the winch assembly 42 in FIG. 1 . The winch assembly 42 may be detachable from the extension bar 40 , so that a single winch assembly 42 and support frame 15 may be used with extension bars 40 of various lengths to create a jack apparatus 10 of varied overall heights.
The lifting frame is comprised of a center bar 16 , which is attached at its front end to a crossbar 17 , where said crossbar and center bar form a T-shaped structure. The crossbar 17 preferably has a length that is equal to or greater than the distance defined by the separation of crossbar rest members 18 and 19 . The crossbar 17 is preferentially perpendicular to the crossbar rest members 18 and 19 , with the terminating ends of the crossbar 17 able to sit on top of the respective crossbar rest members 18 and 19 .
Wheel support means 50 are provided, which are shown as being detachable in FIG. 1 and in FIG. 2 . It should be understood, that the detachability of the wheel support means 50 is considered to be an optional and a more advanced feature, than if the wheel support means 50 was permanently attached and made a part of the terminating ends of the crossbar 17 .
As FIG. 1 shows, the wheel support means 50 is comprised of a main shaft 52 , which supports a spacer 53 , where said spacer 53 is oriented at 90 degrees from the shaft 52 to form a T-shaped configuration. Prongs 54 are attached at each end of the spacer 53 , and project outward away from the apparatus 10 , terminating at a free end. As FIG. 1 shows, the prongs 54 are defined and shown as L-shaped members, in which the horizontal portion of the prong 54 is lower than the spacer 53 and shaft 52 . This is a preferred embodiment, since the horizontal portion of the prongs 54 are able to rest on the ground, while the crossbar 17 of the lifting frame 60 rests on top of the support frame 15 .
The wheel support means 50 may be detachable from cross bar 17 , in which the shaft 52 of the wheel support means 50 has an outer dimension that is at least less than the dimensions defined by insert 51 , which comprises the opening into the interior of crossbar 17 . Shaft 52 is moved into insert 51 until a desired position is reached, at which time both the shaft 52 and cross bar 17 are secured to each other using a securing pin 70 , which is shown in use in FIG. 2 . Such securing pins are common in the art.
The lifting frame 60 , is fixed in position with regard to the vertical frame bar 14 , or where an extension bar 40 is used, fixed in position to the extension bar 40 through a sleeve means. Referring now also to FIG. 5 , a sleeve means comprises the rear end of center bar 16 , in which guide members 31 and 32 are secured to the sides of the center bar 16 , being secured at a slight rearward angle, as compared to a vertical position, so that the guide members 31 and 32 project both upwards, and slightly toward the rear.
The gap defined between the guide members 31 and 32 allow for placement of the vertical frame bar 14 , or the extension bar 40 where one is used, with a top roller 84 placed through the respective holes 33 defined on the ends of guide members 31 and 32 . Referring now also to FIG. 6 , a bottom roller 84 ′ is situated through the side guide members 31 and 32 , in the manner that the top roller 84 is, with the bottom roller 84 ′ positioned above the center bar 16 , but adjacent to the vertical frame bar 14 . The rollers 84 and 84 ′ allow the lifting frame 60 to move smoothly upward and downward along the length of the vertical bar 14 , or any extension bar 40 , where one is used. The vertical frame bar 14 , or the extension bar 40 , when so situated between the guide members 31 and 32 , will provide a guide that the lifting frame 60 can follow in a vertical manner.
Operation of the apparatus 10 is accomplished by attaching the hook 46 , which is located on the end of the strap 45 , to a lifting ring 47 , which is located on the center bar 16 . Lifting ring 47 is depicted as an inverted U-shaped member that is fixed to the top side of the center bar 16 . It should be understood that any manner of connecting the strap 45 to the center bar 16 is understood to be contained within this embodiment. The strap 45 may be tied, or use any other connector means commonly known and understand in the art.
Where the wheel support means 50 are not detachable, the apparatus 10 must be positioned and the small vehicle 81 moved over the lifting frame crossbar 17 until the wheels 80 of the vehicle are placed in between the wheel support prongs 54 . Referring now also to FIG. 3 , once the wheels 80 are in position, apparatus may be actuated so as to raise the vehicle 81 .
One clear advantage of wheel support means 50 being detachable, is that their relative position to the cross bar 17 can vary. This allows for a proper fit to a wide variety of mowers and small vehicle wheel bases, which may vary from vehicle to vehicle. By sliding the shaft 52 along the length of the insert 51 of cross bar 17 , the wheel support means 50 can position the outer side of the spacer 53 against the wheel 80 of the vehicle 81 . Since most small vehicles 81 are relatively light, the vehicle 81 is simply pushed or moved forward so that the wheels 80 are positioned between the prongs 54 . The wheel support means 50 is then adjusted as to width, to ensure the proper fit.
This apparatus 10 is also useful where the vehicle is difficult to move. Referring back again to FIG. 1 , that wheel supports 50 that are detachable, allow the wheels supports 50 to be independently placed around the wheels 80 of the vehicle 81 . Once the wheel support means 50 are jointly position, with their shafts 52 oriented toward each other, the support frame 15 and lifting frame 17 are slid underneath the front end of the vehicle 81 , until the crossbar 17 is positioned adjacent to the ends of the shafts 52 of each of the wheel support means 50 .
Shafts 52 are able to be moved into insert 51 and may be secured using pins 70 . This is a particularly advantageous operation, since small vehicles may not be movable under their own power, and the jack assembly 10 is able to be positioned so it can support the vehicle 81 without the vehicle 81 having to be moved at all.
The lifting of the vehicle 81 is accomplished as shown in FIGS. 3 and 4 . As FIG. 3 shows, the wheel support means are in the proper position, with the prongs 54 making ground contact. Other points of ground contact would likely comprise the front member 20 and wheels 22 . Activation of the winch means 42 , is accomplished by turning the handle 44 which causes the length of the strap 45 to be taken up by the spool 62 . The strap 45 conveys a pulling force through the hook means 46 to the lifting ring 47 which causes the center bar 16 to move upward.
As the center bar 16 , moves upward the weight of the vehicle 81 will be pressing downward on the wheel support means 50 . Movement of the center bar 16 will be limited to vertical movement, as a result of the restrictions applied by the guide members 31 and 32 and top roller 84 and bottom roller 84 ′. Top roller 84 and bottom roller 84 ′ will prevent the lifting frame 60 from tipping forward, as its forward movement will be prevented by the vertical frame bar 14 , or the extension bar 40 if one is used. Removal of the apparatus 10 from the vehicle 81 involves a reverse process, where the vehicle 81 is lowered to the ground, the wheel support means 50 are slid out of the crossbar 17 , and able to be removed from the vehicle area. The support frame 15 and lifting frame 60 are then pulled out from underneath the vehicle.
Referring now also to FIG. 9 and FIG. 10 , an axle hook means 90 is shown, comprising an outer sleeve 91 which has an inner perimeter opening 93 that corresponds to the outer surface of the cross bar 17 . The axle hook means 90 defines a top surface 94 , with an upwardly projecting prong 92 , with the axle hook means 90 able to slide along the length of the cross bar 17 until it is able to be positioned so as to allow the cross bar 17 to engage the axle 78 of a small vehicle. In this use, the wheel support means 50 may not be desired or used, and in the event that they are detachable, they can be removed during this process. The axle hook means 90 is placed over the end of the cross bar 17 , so that the cross bar 17 is disposed through the opening 93 . The projecting prong 92 preferably is fixed to the side of said outer sleeve 91 , and is L-shaped, with a portion of its length extending upwards above the top surface 94 , thus limiting the movement of any axle 78 past said prong 92 . Said prong 92 may also function as the supporting contact point with the axle 78 .
An additional safety feature is also shown FIG. 11 and FIG. 12 , in which the
From the foregoing statements, summary and description in accordance with the present invention, it is understood that the same are not limited thereto, but are susceptible to various changes and modifications as known to those skilled in the art and we therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications which would be encompassed by the scope of the appended claims. | An apparatus with a wheel engagement mechanism for operation with a jack assembly for engaging and elevating two wheels of a multi-wheeled vehicle relative to the ground is provided. The apparatus includes a base, a support member connected to the base, and a wheel support assembly. The wheel support assembly includes wheel supports connected at the ends of the wheel support assembly that extend outward from the wheel support assembly for supporting two wheels of the vehicle. The apparatus also includes an actuation mechanism for selectively raising and selectively lowering the wheel support assembly to raise and lower the vehicle. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present application claims the benefit of Provisional Application No. 62/029,723, filed Jul. 28, 2014, which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to making a garment for use in a direct-to-garment (DTG) printing process. More particularly, the present invention relates to a method facilitating preparation of textiles and/or garments to facilitate use of a DTG printing process to apply graphics to the garments. More specifically, the present invention relates to a method of applying a pretreatment during a textile and/or garment making process to obviate the need to apply the pretreatment to a finished garment in the area to receive DTG printing immediately before DTG printing.
DESCRIPTION OF THE PRIOR ART
[0003] DTG printing is a process using printers utilizing inkjet printing technology to directly decorate, imprint, or customize textiles for any number of purposes. Use of the DTG printing affords direct application of graphics to finished garments (such as t-shirts) more efficiently than traditional screen-printing processes.
[0004] Unlike traditional screen-printing processes, DTG printing allows for the application of an infinite number of graphics (with an infinite number of colors) to garments with limited set-up requirements. Typically, traditional screen-printing processes have significant set-up requirements to facilitate the printing of graphics on garments. For example, a single screen is typically used to apply a single color. Therefore, if a graphic has multiple colors, then multiple screens must be used to facilitate the application of the multiple colors. Unlike DTG printing, traditional screen-printing processes afford limited flexibility. Thus, to be cost effective, traditional screen-printing processes lend themselves to producing large batches of garments with the same graphic printed thereon. In contrast, DTG printing affords the application of any number of different graphics directly to garments with limited set-up requirements. As such, it can be cost effective to produce small batches of garments using DTG printing.
[0005] When using DTG printing processes, darker-colored garments require pretreatment to facilitate application of lighter-colored graphics thereto. Typically, for DTG printing, a pretreatment and then an underbase are applied to a darker-colored garment in order to apply a graphic to the darker-colored garment. The pretreatment is typically a liquid, but, for example, can also be a gel, gel film, or other medium. Thereafter, the ink of the graphic is applied over the pretreatment and underbase to the treated area of the darker-colored garment.
[0006] For DTG printing processes, application of the pretreatment serves (1) to prevent the underbase from soaking into the fabric, and (2) to chemically react with and “gel” the underbase. As such, use of the pretreatment on a darker-colored garment affords better adherence of the underbase to the darker-colored garment. Furthermore, the underbase is typically white or lighter-colored ink, and the underbase provides a barrier between a darker-colored garment and ink of a graphic applied thereto. The underbase serves as a medium for facilitating good color retention, intensity, and wash fastness of a graphic, even a lighter-colored graphic, printed onto the darker-colored garment. As such, the use of the pretreatment and underbase affords use of lighter-colored ink (e.g., white or CMYK colors) to print graphics, even lighter-colored graphics, onto darker-colored garments.
[0007] The pretreatment can also be used on lighter-colored garments for DTG printing processes, where use of the underbase is not necessary. Direct application of the pretreatment on a lighter-colored garment affords better adherence of ink of a graphic applied thereto. Furthermore, the use of pretreatment also facilitates good color retention, intensity, and wash fastness of a graphic printed onto the lighter-colored garment.
[0008] The chemical reaction between the pretreatment and the underbase applied thereover serves in preventing graphic applied thereover from mixing with the underbase. By preventing such mixing, the potential appearance of smearing of the inks applied over the treated area can be prevented. Additionally, the pretreatment and underbase applied to darker-colored garments or the pretreatment applied directly to lighter-colored garments serve in preventing the inks of the graphic applied thereover from running or wicking through the fabric causing the graphic to appear blurred. As such, the use of the pretreatment and underbase on darker-colored garments or the direct application of the pretreatment to lighter-colored garments serves to facilitate application and creation of graphics on garments having crisper, brighter appearances.
[0009] While traditional screen-printing processes have significant set-up requirements in comparison with DTG printing, the application of the pretreatment is not necessary and the application of the underbase can be accomplished during one of the steps of traditional screen-printing processes. To illustrate, the underbase can be applied to garments using conventional screens during traditional screen-printing process. As such, the application of the underbase can be incorporated into traditional screen-printing processes.
[0010] The application of the pretreatment cannot be efficiently incorporated into DTG printing. Applying the pretreatment using DTG printing is cost prohibitive—ink cartridges for the printers for DTG printing are quite expensive, and use of printers for DTG printing typically is reserved for application of the underbase and graphics to garments. Thus, when using DTG printing for garments, the pretreatment must be otherwise applied to garments at least in the area to receive DTG printing via rolling, spraying, or other transfer method (including even screen printing), and the pretreatment must then be dried/cured/fixed to the garment. For example, the pretreatment previously has been applied to entire finished garments via a dipping or soaking process. Thereafter, DTG printing can be used to apply the underbase and graphics over the receptive surface provided by the pretreatment. The time required for application and drying/curing/fixing of the pretreatment can be a drawback of using DTG printing for garments.
[0011] Therefore, there is a need for eliminating the time required for application and drying/curing/fixing of the pretreatment before being able to use DTG printing on garments. The present invention relates to a method of applying a pretreatment during a textile and/or garment-making process to obviate the need to apply the pretreatment in the area to receive DTG printing to a finished garment immediately before DTG printing. The method of the present invention serves in eliminating the need to apply the pretreatment in the area to receive DTG printing immediately before DTG printing.
SUMMARY OF THE INVENTION
[0012] The present invention in a preferred embodiment contemplates a method for making a direct-to-garment printed garment, the method including the acts of supplying a pretreatment, providing a fabric for application of the pretreatment thereto, applying the pretreatment to the fabric, creating all or portions of a garment from the fabric after applying the pretreatment; and printing a graphic on the garment using a direct-to-garment printing process after creating the garment.
[0013] The present invention in another preferred embodiment contemplates a method for treating a fabric with a pretreatment to facilitate printing of a graphic thereon, the method including the acts of applying the pretreatment to the fabric prior to making the fabric into a garment via at least one of a spraying process, a rolling process, a brushing process, a dipping process, and a soaking process, drying the pretreatment onto the garment prior to making the fabric into a garment via at least one of an air-drying process and a heat-drying process, creating all or portions of the garment from the fabric, and after creation of the garment, printing the graphic on the garment.
[0014] The present invention in still another preferred embodiment contemplates a method for treating a fabric with a pretreatment to facilitate printing of a graphic thereon, the method including the acts of applying a dye of a preselected color to the fabric, and applying the pretreatment to the fabric, portions of the acts of dyeing and applying being performed simultaneously, after completion of the applying acts, drying the dye and the pretreatment on the fabric, after completion of the drying act, creating all or portions of a garment from the fabric, and after creation of the garment, printing the graphic on the garment.
[0015] Additional objects and advantages of the present invention will be set forth in the description which follows, and in part will be apparent from review of the following specification, or may be learned by practice of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The following description is intended to be representative only and not limiting.
[0017] As discussed above, the present invention generally relates to making a garment for use in a DTG printing process. More specifically, the present invention relates to a method of applying a pretreatment during a textile and/or garment-making process to obviate the need to apply the pretreatment to a finished garment immediately before DTG printing. The pretreatment is typically a liquid, but, for example, can also be a gel, gel film, or other medium.
[0018] In one preferred embodiment, pretreatment is applied to finished fabrics (such as woven/knitted/milled fabrics) prior to the making of the finished fabric into a finished garment. For example, finished fabric is typically supplied to garment makers in rolls. The finished fabric is cut to shape using a pattern, and then the fabric is assembled into a finished garment. Prior to making the finished fabric into a garment, the pretreatment can be applied thereto using one of a spraying process, a rolling process, a brushing process, a dipping process, and/or a soaking process. Thereafter, the pretreatment is dried/cured/fixed onto the finished fabric. To illustrate, the pretreatment can be dried/cured/fixed using an air-drying process or a heat-drying (or curing) process. Once the pretreatment is has dried/cured/fixed, the pretreated finished fabric can be made into a finished garment. The entirety or portions of the finished garments can be made of the pretreated finished fabric, and all of the portions of the finished garments made of the pretreated finished fabric are ready for DTG printing. Furthermore, both the exteriors and interiors of the portions of finished garments made of the pretreated finished fabric are ready for DTG printing. As such, the need for applying the pretreatment to the garment immediately before DTG printing can be eliminated. Garments made with fabric already treated with the pretreatment are ready for DTG printing after making thereof.
[0019] In another preferred embodiment, rather than applying the pretreatment to finished fabric, the pretreatment can be applied to unfinished fabrics (such as woven/knitted/milled fabrics) during the dyeing process. Dyeing is used to achieve coloration of the unfinished fabric. The dyeing process typically involves dipping and/or soaking the unfinished fabric to impart dye thereto, and the pretreatment can be added during the dipping and/or soaking process. Thus, the dye and pretreatment can be applied simultaneously to the unfinished fabric. Thereafter, the dye and pretreatment are dried to produce a pretreated finished fabric. As such, application of the pretreatment can be incorporated into the process of manufacturing finished fabric. Furthermore, the entirety or portions of finished garments can be made of the pretreated finished fabric, and all of the portions of the finished garments made of the pretreated finished fabric are ready for DTG printing after making thereof. Moreover, both the exteriors and interiors of the portions of finished garments made of the pretreated finished fabric are ready for DTG printing.
[0020] In yet another preferred embodiment, the pretreatment can be applied to natural fibers (e.g., cotton) and synthetic fibers (e.g., polyester) used to make fabric. To illustrate, thread, yarn, or other fibers used in producing fabric can be treated prior to the fabric-making process (e.g., knitting, weaving, or milling). The pretreatment can be applied before, during, or after the dyeing process of the natural and synthetic fibers. Furthermore, such fabric can be manufactured of the pretreated natural fibers, the pretreated synthetic fibers, or a combination of the pretreated natural and synthetic fibers. As such, the pretreatment can be applied prior to the fabric-making process to produce a pretreated finished fabric. Furthermore, the entirety or portions of finished garments can be made of the pretreated finished fabric, and all of the portions of the finished garments made of the pretreated finished fabric are ready for DTG printing after making thereof. Moreover, both the exteriors and interiors of the portions of finished garments made of the pretreated finished fabric are ready for DTG printing.
[0021] By applying the pretreatment to finished fabric, incorporating application of the pretreatment into the process of manufacturing finished fabric, or applying the pretreatment to fibers prior to the fabric-making process, finished garments made from fabric according to these processes require no further processing to facilitate DTG printing. That is, prior to producing a finished garment, the pretreatment can be applied so that the fabric used to make the entirety or portions of the finished garment is prepared for DTG printing. Thus, the method the present invention serves in eliminating the need to apply the pretreatment immediately before DTG printing. As such, the number of steps needed to afford DTG printing on garments can correspondingly be reduced.
[0022] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims. | A method facilitating preparation of textiles and/or garments to facilitate use of a direct-to-garment (DTG) printing process to apply graphics to the garments is provided. The method includes the application of a pretreatment during a textile and/or garment-making process to obviate the need to apply pretreatment to a finished garment immediately before DTG printing. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new and improved apparatus for interconnecting two groups of driers of a papermaking machine.
Generally speaking, the apparatus for interconnecting two groups of driers of a papermaking machine, wherein the groups of driers are suitable for drying a paper web, according to the present development is of the type wherein the paper web is guided together with at least one endless drying wire over heated drying devices, especially drying cylinders or rollers, in such a manner that the paper web is located between the drying wire and an associated drying device. At least two groups of driers successively follow one another in a predetermined direction of travel of the paper web through such groups of driers. At a transition location between the two groups of driers the paper web is guided from the one preceding group of driers into the next following or successive group of driers in such a manner that the opposite side of the paper web, which is situated opposite to the side of the paper web contacted or dried by the preceding group of driers and which faced the drying devices thereof, is now located in the direction of the drying devices of such next following group of driers. In this next following group of driers there is used a different endless drying wire than the endless drying wire used in the preceding group of driers. As viewed in the predetermined direction of travel of the paper web, downstream of the last drying device of the preceding group of driers there is provided at least one deflection roller for deflection of the endless drying wire together with the paper web as well as a following deflection roller for the drying wire which at that location is without or no longer carries the paper web. In the following group of driers at a location upstream of the first drying device of this following group of driers the endless drying wire of such following group of driers is guided over a deflection roller to the endless drying wire of the preceding group of driers and forms together with the paper web and the endless drying wire of the preceding group of driers a contact region. Following separation of the endless drying wire of the preceding group of driers from the paper web the endless drying wire of the following group of driers is guided in conjunction with the paper web over a deflection device belonging to the following group of driers and from which the paper web can then be guided to the first drying device of the following group of driers.
2. Discussion of the Background and Material Information
In the German Petty Patent No. 90 01 209.7, granted Apr. 5, 1990, there is disclosed an apparatus for connecting or interconnecting two groups of driers of a papermaking machine and, when necessary, separating or disconnecting such two groups of driers. The separation of two successive groups of driers, as is known in the papermaking art, can be desired when one group of driers should be stopped for operational reasons, but at the same time the other group of driers should remain operational. With this known solution there can be adjusted, for instance, an upper situated drying wire-guide roll into a number of positions, with the result that there can be varied both the wrap angle of a lower situated suction deflection roller, from where the paper web is transferred from the one group of driers to the other group of driers, and there can be effectuated a separation or disconnection of both groups of driers from one another.
However, prior art web transfer apparatuses of this type are afflicted with the drawback that the transfer of the paper web from one to the other felt must be accomplished along a relatively short path. This can result in uncertainty in the web transfer operation, or there can result, during web transfer, with a corresponding large wrap angle, impairment in the quality of the sensitive paper web.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide an improved apparatus for interconnecting two groups of driers of a papermaking machine in a manner which is not afflicted with the aforementioned shortcomings and drawbacks of the prior art.
Another and more specific object of the present invention aims at providing an improved web transfer apparatus at the transition location between two successive groups of driers, by means of which it is possible to accomplish, with the use of relatively simple means, a positive, quality-protective transfer of the paper web from the drying wire of a preceding or upstream group of driers to the drying wire of the next following or downstream group of driers, while at the same time providing, when needed, the possibility of separating both drying wires from one another through such a distance that these drying wires can move past one another without contacting one another.
Still a further noteworthy object of the present invention concerns the provision of an improved apparatus for interconnecting two groups of driers of a papermaking machine which apparatus is relatively simple in construction and design, extremely reliable in operation, not readily subject to breakdown or malfunction and executes positive and protective transfer of a paper web from one group of driers to the next following group of driers.
As previously explained, the present invention is directed to an apparatus for interconnecting two groups of driers of a papermaking machine, wherein the groups of driers are suitable for drying a paper web. Such apparatus comprises at least two groups of driers successively following one another in a predetermined direction of travel of the paper web through the at least two groups of driers. These at least two groups of driers comprise a plurality of heated drying devices, especially drying cylinders, for drying the paper web, and endless tensioned drying wire means serve for guiding the paper web over the plurality of heated drying devices in such a manner that the 10 paper web is located between the endless drying wire means and an associated one of the drying devices. The at least two groups of driers define a transition location where the paper web is transferred from an upstream located one of the at least two groups of driers to a next following downstream located one of the at least two groups of driers as viewed with respect to the predetermined direction of travel of the paper web through such at least two groups of driers. The paper web is guided from the upstream located group of driers into the next following downstream located group of driers at the transition location between the two groups of driers in such a manner that a side of the paper web which is situated opposite to the side of the paper web which confronted the drying devices of the upstream group of driers now is located in confronting or coacting relationship with the drying devices of the next following downstream located group of driers.
The endless drying wire means advantageously comprises a first endless drying wire for the upstream located group of driers and a separate second endless drying wire for the downstream located group of driers. At least one deflection roller for the first drying wire and the paper web carried thereby is provided for the upstream located group of driers downstream of a last or terminal one of the drying devices of this upstream located group of driers. A further deflection roller is provided for the first drying wire which is arranged downstream of the at least one deflection roller as viewed with respect to the predetermined direction of travel of the paper web through said at least two groups of driers. This further deflection roller serves to deflect the first drying wire at a location where such first drying wire no longer carries the paper web. The downstream located group of driers comprises a deflection roller or roller member arranged upstream of a first drying device of the second group of driers as viewed with respect to the predetermined direction of travel of the paper web through the at least two groups of driers. This deflection roller of the second group of driers guides the second endless drying wire of the second group of driers towards the first endless drying wire of the upstream group of driers such that the second endless drying wire together with the first drying wire and the paper web arranged between the first and second drying wires forms a contact region. A deflection device is provided for the downstream arranged group of driers over which there is guided the second endless drying wire following separation of the first endless drying wire of the upstream located group of driers from the paper web. This deflection device serves for guiding the paper web to the first or initial drying device of the downstream located group of driers.
According to important aspects of the present invention, there are provided, among other things, further devices or means which are capable of altering the course of at least one of the endless drying wires at the region between the at least two groups of driers such that, when necessary, there is possible the separation of the first and second drying wires between the at least two groups of driers.
With respect to a further aspect, the means for altering the course of at least one of the endless drying wires comprises a cleaning roller located above the deflection device which is arranged upstream of the first drying device of the second group of driers and which guides the paper web located between the first and second drying wires. Means serve to move this cleaning roller in the direction of the first drying wire of the upstream group of driers such that in one position of the cleaning roller, in an operating position of the apparatus, both of the first and second drying wires can be placed and retained in contact with one another and in another position of the cleaning roller the first drying wire of the upstream group of driers can be separated from the second drying wire of the downstream group of driers.
Still further, the deflection roller member for the downstream located group of driers is positioned at a location directly upstream of the transition location as viewed with respect to the predetermined direction of travel of the paper web through the at least two groups of driers, and means are provided for altering the position of the deflection roller member in order to augment separation of the first and second drying wires from one another.
It is further contemplated that the at least one deflection roller for the first drying wire located downstream of the last or terminal one of the drying devices of the upstream located group of driers comprises a displaceable deflection roller in order to augment separation of the first and second drying wires from one another.
Moreover, the deflection device provided for the downstream arranged group of driers over which there is guided the second endless drying wire can comprise a displaceable deflection device in order to augment separation of the first and second drying wires from one another.
According to a further aspect of the present invention, an adjustable contact roller is located between the at least two groups of driers which, in an operating position of the apparatus, places and retains the first and second drying wires in contact with one another. This adjustable contact roller is movable away from the first and second drying wires such that owing to tension of the first and second drying wires these first and second drying wires are separated from one another.
Still further, such adjustable contact roller can be constructed as a regulatable or controllable contact roller in order to be able to regulate or control the force with which such adjustable contact roller is applied against the first and second drying wires.
There also may be provided a displaceable deflection means for at least one of the drying wires and the paper web and which is located at the transition location between the at least two groups of driers in order to enable separation of the first and second drying wires from one another. Such deflection means may comprise the at least one deflection roller provided for the first drying wire or the deflection device provided for the downstream arranged group of driers.
As to the means for altering the course of at least one of the endless drying wires such may comprise a suction box located between the at least one deflection roller provided for the first drying wire and the deflection device. Such suction box is advantageously positionable such that due to vacuum conditions prevailing in the suction box both the first an second drying wires and the paper web located therebetween are placed into contact with one another, and in the absence of the vacuum conditions in the suction box the first and second drying wires are released from one another and can move past one another without contacting one another.
This suction box can possesses a substantially concave or convex configuration or even a substantially straight or linear configuration with respect to the first and second drying wires.
Still further, there can be provided means for controlling or regulating the vacuum conditions prevailing in the suction box.
Also the suction box located between the at least one deflection roller provided for the first drying wire and the deflection device can be movable in the direction of the first and second drying wires to such an extent that the suction box comes into contact with a neighboring one of the first and second drying wires and displaces such neighboring drying wire together with the paper web into or towards the other drying wire.
By virtue of the inventive apparatus constructions there is ensured that at the transition region between two successive groups of driers the transfer of the paper web from the preceding or upstream drying wire to the next following or downstream drying wire can be accomplished such that at a certain region or location the paper web is retained at both sides or faces, that is, is retained by both endless drying wires, and thus, such paper web can be positively transferred from the preceding or upstream located drying wire to the next following or downstream located or succeeding drying wire. With certain specific constructional embodiments it is possible to control in a relatively simple manner the force with which the paper web should be pressed against the drying wire or wires, as the case may be. By virtue of the fact that the aforementioned further devices or means can alter the travel course of at least one of the drying wires, it is possible to separate both of the groups of driers. The action exerted for altering the course of the drying wire or wires can be undertaken by direct contact thereat, for example, by using rollers or by application of vacuum or suction conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures there have been generally used the same reference characters to denote the same or analogous components, and wherein:
FIG. 1 is a schematic side view of a first exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 1a illustrates the apparatus of FIG. 1 in an open condition between the two successive groups of driers;
FIG. 2 is a schematic side view of a second exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 2a illustrates the apparatus of FIG. 2 in an open condition between the two successive groups of driers;
FIG. 3 is a schematic side view of a third exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 3a illustrates the apparatus of FIG. 3 in an open condition between the two successive groups of driers;
FIG. 3b illustrates a further modification of the apparatus of FIG. 3 and again depicts such in an open condition between the two successive groups of driers;
FIG. 4 is a schematic side view of a fifth exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 4a illustrates the apparatus of FIG. 4 in an open condition between the two successive groups of driers;
FIG. 5 is a schematic side view of a sixth exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 5a illustrates the apparatus of FIG. 5 in an open condition between the two successive groups of driers;
FIG. 6 is a schematic side view of a seventh exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine;
FIG. 6a illustrates the apparatus of FIG. 6 in an open condition between the two successive groups of driers;
FIGS. 7, 7a and 7b respectively schematically depict different constructions of suction boxes which can be used in the various embodiments of the present invention;
FIG. 8 is a schematic side view of an eighth exemplary embodiment of apparatus for interconnecting two groups of driers of a papermaking machine; and
FIG. 8a illustrates the apparatus of FIG. 8 in an open condition between the two successive groups of driers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the different embodiments of apparatuses for interconnecting two groups of driers of a papermaking machine and the papermaking machine itself have been depicted therein, in order to simplify the illustration, as needed for those skilled in the art to readily understand the underlying principles and concepts of the present invention.
With more specific reference now made to the drawings, it is here pointed out that FIGS. 1 to 6a and 8 and 8a in each case depict the transition or web transfer region or location between a preceding or upstream arranged group of driers 1 and a next following or succeeding or downstream arranged group of driers 2. In each of the groups of driers 1 and 2 there are used drying cylinders or rollers 3 and 4, respectively, and tensioned endless drying wires 5 and 6, respectively, or equivalent drying elements as generally known in the papermaking art. Usually, although not necessarily, deflection rollers 7, 8 and 9, here depicted by way of example as suction rollers, are located between the drying cylinders 3 and 4. By means of these deflection rollers 7, 8 and 9, defining deflection devices, the drying wires 5 and 6, together with the paper web, are collectively turned or deflected and then can be delivered to the next following or downstream located drying cylinder of the associated group of driers 1 and 2, as the case may be. As concerns the present invention, particular attention is to be paid to the last deflection roller 8 of the preceding or upstream group of driers 1 as well as to the first deflection roller 9 of the next following or downstream group of driers 2, and furthermore, to the last wire guide or deflection roller or roll 10 of the preceding group of driers 1 and the first wire guide or deflection roller or roll 11 of the next following group of driers 2.
With that general background in mind as concerns the different exemplary embodiments of apparatuses of the present development, and now directing specific attention first to the embodiment of FIGS. 1 and 1a, it will be seen that a contact or press roller or roll 12 is located between both deflection rollers or deflection devices 8 and 9 of the here depicted two successive groups of driers 1 and 2. In its working position as depicted in FIG. 1, this contact roller 12 is pressed or urged against the outgoing or outbound portion of the endless drying wire 5. In order to move such contact roller 12 the same may be provided with any suitable adjustment or positioning device, like for instance a displaceable or pivotable adjustment lever, such as the lever 70 associated with a cleaning roller 13 to be considered shortly with reference to FIGS. 3, 3a and 3b. Furthermore, as viewed in the predetermined direction of travel of this drying wire 5, as generally indicated by the arrow 50, a region is present downstream or after such contact roller 12 where both of the first and second drying wires 5 and 6 and the intermediately situated paper web form an integrated or composite structure. By adjusting the force with which there is applied the contact or press roller 12 in the direction of the arrow 52 against the endless drying wire 5 there can be produced a regulating action as concerns the connection or contact between the paper web and endless drying wire. Furthermore, as will be seen by referring to FIG. 1a, by appropriately displacing or pivoting the contact roller 12 in the direction of the arrow 54 away from the drying wires 5 and 6 there is achieved a separation between the two groups of driers 1 and 2.
The modified embodiment depicted in FIGS. 2 and 2a constitutes a similar arrangement to that shown in FIGS. 1 and 1a, wherein, here however, the contact roller 12 is pressed against the second drying wire 6 of the next following or downstream arranged group of driers 2 as considered with respect to the direction of travel of the paper web between the two successive groups of driers 1 and 2. It will be apparent that, just as in the prior arrangement of FIGS. 1 and 1a, the paper web moves from the first or upstream group of driers 1 to the next following or downstream group of driers 2, in other words, from the left to the right of the showing of the drawings. Moreover, upon opening the two groups of driers 1 and 2, here not only the contact roller 12 but also the wire guide or deflection roller 10 of the preceding group of driers 1 is shifted in position, as particularly evident by inspecting FIG. 2a. In particular, the wire guide roller 10 is displaced within its displacement slot or guide 56 towards the left from the position shown in FIG. 2 and the contact roller 12 is displaced in its displacement slot or guide 58 towards the right of the position shown in such FIG. 2, resulting in separation or opening of the drying wires 5 and 6, as shown.
With reference now to FIGS. 3, 3a and 3b, there is here beneficially employed for separation of the two successive groups of driers 1 and 2 from one another the cleaning roller or roll 13 which is usually required in any event. This cleaning roller 13 is pressed against the outbound drying wire 5 of the first or upstream located group of driers 1 by means of the associated displaceable or pivotable lever 70 constituting an adjustment means or element for such cleaning roller 13. It will be observed that this cleaning roller 13 contacts the drying wire 5 at the region thereof moving away from the connection or contact region or location between the two groups of driers 1 and 2 and thus cleans such outbound region of the drying wire 5. When necessary or desired for the separation of the groups of driers 1 and 2 from one another, this cleaning roller 13 is displaced more intensely into contact with the neighboring drying wire, here, for example, the drying wire 5, so that such drying wire 5 positively lifts-off of the coacting drying wire 6 of the downstream or next following group of driers 2. As shown in the arrangements of FIGS. 3a and 3b, by displacing a lower wire guide roller (FIG. 3a) or by displacing an additional or supplementary separation roller 14, in the direction of the indicated arrows 60, there can be accomplished the complete separation of the drying wires 5 and 6 of both groups of driers 1 and 2 from one another.
Just as was the case for the embodiment of FIGS. 1 and 1a, in the modified embodiment depicted in FIGS. 4 and 4a there also can be provided a contact or press roller or roll 12 between both of the deflection or turning rollers 8 and 9. Here also there is formed a coherent or composite region containing both of the drying wires 5 and 6 and the paper web sandwiched therebetween. In the event that the two groups of driers 1 and 2 are to be separated from one another, then as depicted in FIG. 4a apart from appropriately shifting the displaceable contact roller 12 away from the associated drying wire, here the wire 6 in the direction of the depicted arrow 62, also the displaceable deflection roller 9 is displaced away from the drying wires 5 and 6, and specifically to the right of the showing of FIG. 4a away from the drying wire 5 in the direction of the arrow 64, resulting in very short displacement paths of these displaceable rollers 9 and 12 in order to effectuate opening of the two groups of driers 1 and 2. The contact roller 12 can be adjustably mounted in any suitable manner, as, for example, shown in the exemplary depicted arrangement of FIGS. 2 and 2a, in a slotted guide 58. Equally, the deflection roller 9 can be appropriately displaceably mounted in any suitable manner, as, for instance, upon a displaceable or pivotable lever or equivalent structure, like the adjustment or displacement lever 70 previously considered with respect to the cleaning roller 13 shown in FIG. 3.
The apparatus constructions of the embodiments depicted in FIGS. 5 and 5a and 6 and 6a, respectively, do not require the use of any displaceable or movable rollers to accomplish the separation and closing, as the case may be, of the two groups of driers 1 and 2. Here there is instead used at least one suction box 16 which is operated under vacuum or negative pressure conditions, which can be controlled by any suitable vacuum control or regulating means, generally indicated, for instance, in FIG. 7b by reference numeral 66. This at least one suction box 16 is mounted at a location between both of the deflection rollers 8 and 9, and specifically in such a manner that the drying wire 6 of the next following or downstream group of driers 2, moves in close contact with or at a close spacing to and past such suction box 16. The drying wire 5 of the preceding or upstream group of driers 1 travels, in turn, at a slight spacing from the drying wire 6 past the suction box 16 without contacting such drying wire 6 and the paper web located thereupon.
Continuing, as shown in FIG. 5, in the event a vacuum is applied to the suction box 16, then the drying wire 6 and the paper web located thereon or both drying wires 5 and 6 and the therebetween sandwiched paper web are collectively drawn against or towards such vacuum box 16. As a result, there can be accomplished in an ideal fashion the transfer of the paper web from the preceding drying wire, here the first endless drying wire 5, to the next following or downstream located drying wire, here the second endless drying wire 6. With these embodiments it is possible to simply separate or open the two groups of driers 1 and 2 by shutting-off the vacuum of the suction box 16.
As particularly well depicted in the embodiment of FIGS. 6 and 6a, under certain circumstances it can be advantageous to construct the suction box 16 to be displaceable in the direction of the drying wires 5 and 6, as indicated by the arrow 68, through the use of any suitable displacement mechanism, such as previously considered herein. Such use of a displaceable suction box 16 can simplify or facilitate the separation of and connection between, as the case may be, the two groups of driers and 2, even though such modification requires a somewhat greater equipment expenditure owing to the displaceability of the suction box.
FIGS. 7, 7a and 7b respectively depict three different contours Or constructions of suction boxes 16', 16'' and 16'41 . More specifically, FIG. 7 depicts a concave suction box 16', FIG. 7a a convex suction box 16", and finally, FIG. 7b a suction box 16''' having a substantially linear course or extent. By selecting an appropriate contour of the employed suction box there can be minimized the wear at the front edge of the suction box and there can be optimized the protection of the paper web which is guided in sandwich configuration between the coacting drying wires.
Finally, with reference to the further embodiment depicted in FIGS. 8 and 8a, which is in principle similar to the arrangement of FIGS. 1 and 1a, there is here, however, depicted by way of example and not limitation that it is possible to position the deflection or turning rollers 7, 8 and 9 above or below the drying devices, specifically the drying cylinders 3 and 4, as shown, without departing from the inventive concepts. For instance, in the embodiment of FIGS. 1 and 1a the deflection rollers 7 and 8 of the preceding or upstream group of driers 1 are shown located below the neighboring drying cylinders 3 whereas the deflection rollers 7 and 9 of the succeeding or downstream group of driers 2 are located above the drying cylinders 4, but the reverse arrangement of the deflection rollers 7, 8 and 9 in relation to the corresponding drying cylinders 3 and 4 of the two groups of driers and 2, respectively, is shown for the modification of FIGS. 8 and 8a. The same observations hold true for the other exemplary embodiments previously considered.
While there are shown and described present preferred embodiments of the invention, it is distinctly to be understood the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | The apparatus for interconnecting two groups of driers of a papermaking machine serves to interconnect two successive drying sections through which successively travels a paper web which is dried by such successive drying sections. When needed or desired, such interconnection must be interrupted. For this purpose there are used additional elements which are capable of bringing about a separation of the endless drying wires associated with the respective web drying sections and, at the same time, during normal operation, that is, during the transfer of the paper web from the one to the other drying section, affording a regulatable operation capable of retaining the quality of the paper web. Thus, for this purpose there are proposed the use of adjustable rollers and also suction boxes operated under vacuum conditions. | 3 |
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